Synchronizing the Retail Supply Chain

Abstract

Dit proefschrift ontwerpt een retail supply chain, die beter en goedkoper is dan de gangbare. Dit wordt bereikt door de distributie te synchroniseren op de productie¬momenten. Goederen zouden direct uit productie al stroomafwaarts moeten bewegen, van fabrikant naar retailer, tegen lage kosten, in volle pallets en in volle auto’s en in hoeveel¬heden die groot genoeg zijn om de vraag tot het volgende productiemoment te dekken. Door de formules van de "Krantenverkoper" en die van de economische ordergrootte (EOQ) aan te passen aan een multi-echelon divergerend distributienetwerk, kan ook theoretisch worden bewezen dat het stroomafwaarts positioneren van voorraden inderdaad optimaal is en dat de voorraden daardoor zullen dalen. De huidige magazijnen van de leveranciers kunnen worden gereduceerd tot overslagpunten, waar goederen van de verschillende fabrieken van een leverancier worden samengebracht om rijden met vollere vrachtwagens mogelijk maken. Kleinere hoeveelheden kunnen leveranciers beter afleveren bij het dichtstbijzijnde distributiecentrum van een retailer, waarna de retailer zelf het deel met bestemming elders verder vervoert. Tenslotte kan de winkelbevoorrading worden aangepast aan de schapruimte, waardoor de werkwijze in de distributiecentra kan worden gerationaliseerd.Piet van der Vlist (1947) was born in Ouderkerk aan den IJssel. He received his high-school diploma from the Marnix Gymnasium in Rotterdam. Also in Rotterdam he graduated as Electronics Engineer at the University of Applied Sciences. He obtained a Master of Science in Electronics at the Delft University of Technology and one in Management Sciences at the University of Twente. He worked 15 years with the Dutch Ministry of Defense on the design and realization of the first generation digital communications systems. Then he joined Bakkenist Management Consultants and later Deloitte Consultancy, together for over 20 years. As consultant he was involved in numerous projects on Data exchange and Supply Chain redesign. Besides that, he was for 11 years (part-time) professor in ICT and Logistics at the Eindhoven University of Technology. Piet wrote and edited several books on data exchange and published numerous articles in business and scientific journals. A fairly good overview of his scientific career can be found in the "Liber Amicorum" that his friends wrote when he left Eindhoven University1. His current research interests lie in the design and management of retail supply chains, all the way from production down to the shelves. He found that the supply chain with the overall lowest costs requires synchronization of distribution to production and not the other way around as current practice seems to dictate. When he had to quit his jobs for health reasons, he finally found the opportunity to devote his time to research and extend the theory that supports Supply Chain Synchronization. He programmed built to purpose simulation models to get a better insight in the dynamics of synchronized supply chains. He joined both the Rotterdam Erasmus University to work with Professor Jo van Nunen and the Eindhoven University of Technology to work with Professor Ton de Kok. This PhD thesis is the result of that effort.This thesis is a design of a retail supply chain that is better and cheaper than the usual one. This is achieved by synchronizing distribution to production. Right from production goods should move downstream the supply chain at low cost in full pallets and in full truckloads, in quantities large enough to cover the needs till the next production run. By extending both the Newsvendor- and the EOQ-formulae to a multi-echelon divergent network, it can be proved that such forward positioning of inventory indeed is optimal and that overall supply chain inventories will drop. The suppliers’ warehouses become stockless cross docking points, where goods from the supplier’s various sourcing plants are brought together to consolidate them into full truckloads. Whenever suppliers deliver lower volumes, they better bring these goods to the nearest retailer’s facility; thereafter the retailer himself should move these goods onward to the proper destination within the retailer’s network. And finally shop replenishment should be rationalized based on shelf coverage, so as to enhance the retailer’s warehouse operations