羅蘭貝格為大眾汽車(chē)(日本)的咨詢(xún)

Improvingthelogisticsforspareparts–Proposal–VOLKSWAGENGroupJapanKKFebruary26,1999RolandBerger&PartnerJapanLtd.–InternationalManagementConsultantsBarcelona–Beijing–Berlin–Brussels–Bucharest–Budapest–BuenosAires–Delhi–Düsseldorf–Frankfurt–HamburgHelsinki–HongKong–Kiev–KualaLumpur–Lisbon–London–Madrid–Milan–Moscow–Munich–NewYork–ParisPrague–Riga–Rome–S?oPaulo–Shanghai–Stockholm–Stuttgart–TelAviv–Tokyo–Vienna–Zurich1-CoverpageJPN-6005-95000-01-01Contents PageA.Background: Thesparepartsbusinessbecomesincreasingly 3 importantforVWinJapan

B.PotentialareasforlogisticsimprovementfromRB&P'sperspective 7

C.Settingtheobjectivesoftheproject 14D. Projectapproachandschedule 16E. Teamandbudget 19JPN-6005-95000-01-01A.Background:Thesparepartsbusinessbecomesincreasingly

importantforVWinJapanJPN-6005-95000-01-01Changingthesaleschannelin1992resultedinincreasingsalesvolumeAutomobileunitsregisteredandinoperationinJapan[VWGroup]ca.4721988198919901991199219931994199519961997Unitsinoperation['000]

020406080Newunitregisteredperyear['000]CAGR-22.5%CAGR24.7%VWAudiJapan(VAN)EstablishedToyotaDuostartedYanasequittedsalesVANgotJAXSources:AutomotiveYearBook,Nikkei,DailyAutomotiveNewspaper1997JPN-6005-95000-01-01PartssalesincreasedoverproportionallytotheincreaseinunitsinoperationSource:CPDPartssalestrend[\mill.]38940643247219941995199619976858941,0161,12019941995199619971998Unitsinoperation[\mill.]CAGR6.7%CAGR17.8%JPN-6005-95000-01-01NewmodelswillraisetheinventorylevelinCPDFuturemodelsVWPolo(2dr,4dr)BeetleGolf(CLi,GLi,GTI,GTX,W,Cablio)LupoPassart(1.8,1.8T,V6,W1.8,W1.8T,WV6)BoraSharanOthers(?)A3(1.8,1.8T)TT?A4(1.8,2.4,2.4Q,2.8Q,1.8TQ,A2.4,A2.4Q,A2.8Q)A6(2.4,2.4Q,2.8Q,A2.4,A2.4Q,A2.8Q)A8(3.7,4.2Q)CurrentLine-upModelLine-upBentleyBugattiJPN-6005-95000-01-01B.PotentialareasforlogisticsimprovementfromRB&P'sperspectiveJPN-6005-95000-01-01TheactuallogisticssystemprovidesdistinctiveadvantagesbutpotentialshortcomingshavetobereviewedhighexperienceofKimuraUnityinlogistics(Toyota)fastdistribution97%overnightdeliveryhighreliabilityhighcostlevel(?)excessinventory(?)overstaffinginCPD(?)concernsonpackaging(?)materials(Cartonbox)JPN-6005-95000-01-01DistributionistotallyoutsourcedtoKIMURAUNITYincludingsubcontractingtofleetoperations.Question:HowmuchmarginisjustifiedforKimura?NagoyaPortByshipGermanyCPD240-feetcontainersperdayKIMURAUNITYOutsourcingFahrendealersToyota’sDepotKamigoDuoDealersToyotadistributionnetworkKIMURAUNITY(40%)BY8fleetoperatorscontrolledbyKIMURAUNITY(60%)PhysicaldistributionsystemAirportByairSource:CPDJPN-6005-95000-01-01KIMURAUNITYselectsthefleetoperatorsandcontractsthetariff.

Question:Isthesplit-uptodifferentregionalsubcontractorsreallycosteffective?TransportationSystemMatsuokamanHokkaidoAreaDaiichiTohokuAreaSeinoKantoAreaTonamiHokurikuAreaFukuyamaKansaiAreaS-LineGifuKyushuAreaSeibuKoukuAirCargoShinkyoAutoForShinkyoGroupTokoroYanaseKIMURAUNITYCPDSource:CPDOperatorsseemtobeselectedaccordingtoregionalcriteriaCustomerrequests?JPN-6005-95000-01-01Atotalof61employeesarecurrentlyworkingatCPD.Question:Isthereanycostreductionpotential,consideringbenchmarkingwithcomparablewarehousesCPDOperationOrganizationReceiving(4)Inspection&Unpacking(8)Receiving&InspectionOpenStorage&Rack(13)AutomatedStorage(5)Replenishment&PickingPackingforMedium/LargeParts(4)PackingChubuKogyo(34)Sorting(4)PackingforSmallParts(5)PackingShipping(8)DeliveryControl(2)Shipping&DeliveryKIMURAUNITY(19)CPD(8)Note:FiguresintheparenthesisshowthenumberofstaffinchargeSource:CPDJPN-6005-95000-01-01Thecurrentoccupancyrateisveryhigh.Question:Whereisthebottleneckandhowtoimproveit?Source:CPD#oflocations#oflocationusedOccupancyShuttle&Server5,9783,97066.4%HorizontalM/R12,96010,76883.1%VerticalM/R3,4963,07688.0%Binrack24,81819,80079.8%Paletterack5,5104,53682.3%Openstorage1,48579653.6%Flammablearea91356561.9%Total55,16043,51178.9%Note:averagefiguresbetweenAug.1998andOct.1998StoragecapacityJPN-6005-95000-01-01Theinventorylevelshowssharpdropswhichmaybecausedbycrappingorpartswrite-off.Question:Howcaninventorylevelbeoptimizedandwrite-offsbereduced?(withanincreasingnumberofmodels)InventorytrendinCPD303234363840Jan-95Mar-95May-95Jul-95Sep-95Nov-95Jan-96Mar-96May-96Jul-96Sep-96Nov-96Jan-97Mar-97May-97Jul-97Sep-97Nov-97Jan-98Mar-98May-98Jul-98Sep-98Inventory['000]ScrapSource:CPD1995199619971998JPN-6005-95000-01-01C.SettingtheobjectivesoftheprojectJPN-6005-95000-01-01TheobjectiveofthelogisticsprojectshouldcoverthreeinterrelatedissuesThesubcontractorissueTheinventoryissueTheservicelevelissue123Clarifyrealisticalternativestotheactualsystemevaluateregionalsplitupoftransportcontractorsassesstariffadequacyoftransportcontractorsandcostreductionpotentialcategorizationofnecessarysparepartsavailability(volume/time)EvaluateanddevelopattractivescosteffectivenessofCDPoperations:staffinginventorylevelandbottlenecksscrapandwrite-offlevelJPN-6005-95000-01-01D.ProjectapproachandscheduleJPN-6005-95000-01-01TheprojectwillconsistofthreephasesLogisticalauditImplementationNewlogisticaldesign123logisticalsystemcostlevel/benchmark,comparisonoftariffstructureservicelevelcapitalutilizationlogisticalsystem(plan)costreductionproposalsservicelevelimprovementoradaptationinventoryreductionActualprojectscopeImplementationprojectJPN-6005-95000-01-01ProjectScheduleOrientationInternalinterviewsDataAnalysis-transportation-inventoryExternalinterviews-users-competitors-contractorsPlandevelopmentPresentation1stweek2ndweek3rdweek4thweek5thweekJPN-6005-95000-01-01E.TeamandbudgetJPN-6005-95000-01-01ProjectOrganizationTheoverallresponsibilityfortheprojectwillbewithDr.EugenvonKeller,managingpartneroftheJapanofficeofRolandBerger&Partners.TheprojectwillbemanagedbyMr.MasakazuShima,principalintheTokyooffice,withspecialresponsibilityandexperienceinlogisticsandoperations.Furthermore,RolandBerger&Partnerswillincludetwootherconsultantsspecializedinlogisticsandoperationsintotheproject.AstrongcooperationwithVW-groupisneededduringallphasesoftheproject.Wethereforerecommendtoinclude1or2staffmembersofVWintotheprojectteamJPN-6005-95000-01-01BudgetTheprofessionalfeefortheprojectwillamountto9,800,000yenplusVAT5%