Beruflich Dokumente
Kultur Dokumente
A Pain
In the (Supply) Cha in
It's that time again, the end of the quarter, and Exceso is scrambling
to meet wildly ambitious sales goals. The company's aggressive
promotions are pulling in retai lers, but does d isaster loom ?
MONDAY, 10:42 AM
Manufacturing Facility 14,
Exceso Corporation
R. Foley Vinton, CEO of Exceso, shoves This is, in fact, what took place, but
through the heavy plastic strips onto Foley's desc ription leaves out the cause.
the factory floor, already wearing his A massive, yet finicky, injection molder
hard hat and goggles, earplugs draped had once again developed a mysterious
by John Butman around his neck, and is relieved to hear inability to create the key piece of Ex-
the din of manufacturing. He turns and ceso's flagship product, the ClickZip-
holds back the strips so his visitor, ana· Plus. An image of a line of hiking Cub
Iyst Andrea Valdini -similarly prepared Scouts, backed up behind the den's slow-
for the tour - can step through. est member, flashes through Foley's
"How many shifts are you running?" head; it is the metaphor that illustrates
she shouts above the noise. the effects of manufacturing bottle-
"Three," replies Foley, not smiling, all necks, remembered from Eli Goldratt's
business. "We're essentially running at book The Goa/.
full capacity:' flSO now we're running flat out to fill
Andrea makes a note on a folded orders." Foley pauses before the molding
index card with a tiny pen. "How long machine, whose jaws open as if on cue,
have you been doing that?" revealing 148 perfect plastic parts in the
Foley grimaces and decides to dis- distinctive nickel and cobalt colors of
tract her with a partial truth. "Well, the ClickZ ipPlus. He decides not to
we actually were down last week,n he re- mention that the machine is producing
veals, pointing at a passing auto- a yield of 98%, because further ques-
mated material-delivery vehicle. tioning might lead to the admission that
"Installing some new robotics." it is running at only 60% of its optimal
MAY 2002 31
HBR CASE STUDY· A Pa i n in the (S upply) Cha in
speed. "It all depends on how you define Alice nods. "Correct. But we're buy- WEDNESDAY, 7:49 AM
'essentially full capacity: " Foley thinks. ing at a 6" discount to our standing Underground Parking Garage,
"Are you going to meet your sales price." She sinks her teeth into the fajita. Exceso Tower
forecast for the quarter?" "Exceso must be a little desperate."
"Our guideline is 9" sales growth. "They're also committing to an in- Martin Wu pulls into the garage, driving
That's what I told you analysts, and crease in co-op dollars for an FSI . And a little too fast, considering that he's run-
that's what I've said to my organization." that's not all." She looks at Wendell as if ning early for his breakfast mee ting
Foley smiles. "And they generally take challenging him to guess what other with a customer. But as Exceso's head of
my sales guidelines to heart.' concessions she might have wrangled. sales, his driving seems to refl ect his
"How can Exceso acrueve such growth Wendell tries to imagine the most pre- keen awareness that the pace of every-
in trus economic climate? And with the posterous possibility. "They've agreed to thing has acce lerated, including the
kind of price pressure you're getting deliver on Sunday?" speed at wruch sales can turn sluggish.
from retailers?" liAs a matter of fact, they have," says Martin runs up behlnd a shiny, new
R. Foley Vinton, who considers rum- Alice coolly, as if this buying coup were pickup truck with a tidy tonneau cover
self a collaborative and progressive CEO, nothing unusual. and stainless steel step-bars and real-
ponders Andrea's question and can think Wendell now turns critical. "Wait a izes, too late, that Foley Vinton is the
of only one thing: the essential, and exas- minute. We don't have warehouse space driver. Martin considers driving right on
perating, difference between customer for 3,000 cases, so we'll have to pay to through the garage so he can avoid the
orders and consumer sales. park them somewhere else. Plus, we'll inevitable question that Foley will ask as
get whipped for tying up so much capi- soon as they park but decides instead to
tal. That discount could end up costing face the issue.
TUESDAY, 1 :38 PM us more than it saves." "So, Martin!" Foley calls, waiting for
Midwest Regional Headquarters, "That would be true," Alice nods, "if Martin to lock his car and join him for
Flemings ValuMart I planned to keep the whole shipment. the walk to the elevators. "How are we
But I don't.' She leans forward. "The Ex- doing? Are we making OUT number?"
Alice Dias chuckles to herself as she ceso rep for the southern region is only Martin looks Foley in the eye. "No,
swipes her employee ID through the offering a 4%discount, and, because of Foley. We're not."
card reader at the end of the fajita line. their lower volume, the cost of south- Foley retunls Martin's keen gaze. "But
She is late for lunch and hungry because ern's four-pack is already about six cents we set the target based on your forecast
she's been on the phone with the Ex- higher than ours in the Midwest. I'm data. We all agreed to the plan.'
ceso district sales manager for more going to ship half of trus order straight IIYes. But that was raw data. It con-
than an hour, haggling over purchase through to them, so they can take ad- tained anomalies."
terms for the ClickZipPlus. Alice is de- vantage of the discount. Then I'm going 4< How far off are we?"
lighted to see that Wendell, her brainy to unload another 500 cases on our di- "We'll do well to grow sales by 3",'
intern from business school, is still verter friends at VXT, at our cost but Foley says nothing, but his face hard-
there, engrossed in a worn copy of Com- with a first option to buy back at a 3" ens slightly. "I hear this every quarter,"
petitive Strategy. premium withln 60 days.' be thinks. "And every quarter we make
"You want to know how to work the Wendell gasps at the beauty of Alice's the number. What I need to do is ac-
supply chaIn?"she says. "You should talk plan. "So we have a handy source of in- knowledge Martin's concerns, express
tome." ventory but with no carrying costs. If we my appreciation for his hard work, ap-
"Get a good deal?"Wendell asks. buy back, the price will still be lower peal to his competitive spirit, challenge
"I committed to 3,000 cases of the than Exceso's standing price!' him to exceL"
four~pack !' "Leaving us with 1,000 cases for the Martin anticipates Foley's thoughts.
"What?' Wendell is aghast. "Correct quarter, which we can run at a special "Welre doing everything we can. We're
me if I'm wrong, 0 great mentor, but I promotion. If that doesn't increase vol~ offering discounts and flexible terms.
seem to recall that we sold only 1,800 ume by 10%, I would be extremely sur- We've got some good display ideas.
cases in the last two quarters combined.' prised," Alice says. We're trying to crack some new ac-
Wendell smacks Competitive Strategy counts. We even agreed to Sunday de-
John Butman ;s a communications con- shut. "Do you think Mr. Foley Vinton livery for Flemings:'
sultant, speech writer, and the author of knows how his people meet his sales Foley nods. "Great. And we've still got
four business books, including the satire targets?" a few weeks."
The Book That's Sweeping America! or "He knows only too well J" Alice says "Butllook, Foley,"says Martin,almost
Why I Love Business (John Wiley, 1997). and then remembers, "Did I mention plaintively. "Tbere's really only one way
His first novel, lbwnie, will be published that they also gave me two tickets to the to make the number. And I thought we
by the Permanent Press in August. u.s. Open?" had agreed to stop load.ing~
-=_..0/ _ -
MAY 200 2
33
HBR CASE STUDY. A Pain in the (Supply) Chain
'-'---------
"We have agreed -in principle. And of ClickZipPlus;' she says. "There are which includes reps from every region;
we will, when the timing is right." none on display:' staffers from promotion, display, fore-
"The timing will never be right." 'II know:' replies the manager. "We casting, and key accountsj and assorted
"Yes it wi U," says Foley, mustering have none at all:' others who've wandered in to offer their
all his well·known calm and rational- "When will you have them?" two cents.
ity. "Anyone of a number of factors "We'U have plenty of four-packs "If we go with deeper discounts:' says
will make the timing better than it is Monday;' the manager says helpfully. a ve teran sales manager, "we'll move
now. The new-product launch could "Special price." more product. Duh! But it's not going to
give us the window. The share buyback "No eight-packs?" sell through. It'U end up in their ware-
could. The economy could tum around." "They're having problems with the house. We know that. And then we'll be
He puts a heavy hand on Martin's shoul- eights:' he reveals." I'll discount a double selling refills and dead SKUs and two-
der. "What we need right now is a lift in four-pack if you want." packs and eights for the next two
the share price. To get that, we need 'Iyou only have one of them:' months."
some good news. And the best news is The manager takes on a consultative "Could I just ask a question? Do we
strong sales." tone. "Well, we've got other brands to still need to make a profit?" asks Fred,
Martin says nothing, but he looks
doubtful.
I'You'1I find a way, Martin. You and
your people always do," Foley says. " If we go with deeper discounts, we'll move more
"You're masters at the game."
Martin hits the up button, knowing product. Duh! But it's not going to sel l through.
the discussion is over. As they wait for It'll end up in their warehouse. We know t hat:'
the elevator, he gazes blankly at foley's
distant pickup, gleaming in the bluish
light of the luminaire. "Quite the vehi-
cle you've got there, Foley:' he says. "Co- choose from. The Carlex eight-pack is another manager, with a fine tinge of
balt blue:' a little cheaper, anyway:' sarcasm.I'We used to have this neat
Foley squeezes Martin's shoulder. "What about the quality?" thing called margin. It was really nice.
"Once we have good news, then we can "It's just as good?' I'd like to have that agai n:'
take the hit and clean things up:' "I'Utry it,"says Andrea. Martin almost laughs. "We still make
The manager nods, understandingly. a margin at the deeper discount."
"Exceso's a great company, but I don't "Even afrer you figure in the cost of
WEDNESDAY, 9:27 AM think they can keep this up much display and sampling?" asks a younger
Flemings ValuMart, Near longer!' manager, with a frown.
McKenna, Palash & Zweig Securities "Can't keep what up much longer?" "Not sure:' Martin admits. "But we do
Andrea asks, a little annoyed, but not before the cost of sales."
Andrea Valdini - AA batteries and a tin quite sure why. "What about manufacturing over-
of mints already in hand - wanders The manager wags his hands back runs?" asks the veteran."Number14 was
down the aisle in search of a pack of and forth, as if to suggest some kind of shut down all last week, and now they're
tissues. Although she's on a personal less than desirable behavior. running three shifts:'
errand, she's always in analyst-data- Is it possible that this store manager "Why are they making so much prod-
coUection mode and can't help but be knows more about Exceso than I do, An- uct?" The young salesperson is gen-
diverted from her mission by a glint of drea wonders, more than Foley Vinton uinely concerned.
nickel, accented by cobalt. A single four- has told me? "How do you feel about "They must have believed our fore-
pack of ClickZipPlus hangs forlornly their stock?" she asks, half seriously. cast:' cracks Fred.
from its peg, surrounded by a grove of The manager opens his hands in a "I think we should just leave the price
empty pegs where other four-packs and gesture that says, nWho knows?" where it is, sell what we can) take our hi4
eight-packs should have been proudly and clean out the shelves:' says the vet-
displayed. A few of the pegs normally re- eran."It's time to send Foley a message."
served for Exceso products have been THURSDAY, 6:S2 PM "Then Foley will send a little message
claimed by competing manufacturers, Sales Conference Room, to us," Fred repHes. I, 'Dear Fred. Thanks
and the single ClickZipPlus pack looks Exceso Headquarters for your many years of valued service.
besieged. Now clean out your desk:"
Andrea finds a manager at the back of Martin Wu is presiding over a boister- "Alright, listen," says Martin. "Foley
the store."J'm looking for an eight-pack ous meeting of his extended sales tearn, has made a promise to the analysts. The
analysts have made a promise to the doesn't adjourn the meeting, but every- not alone in that. They're due for a rally.
shareholders. I've made a promise to one knows it's over. And if they get one, they should be able
Foley. We have to do whatever it takes to reduce their reliance on loading, if
to make plan!' that's what they're doing. I can't tell
At that moment, Vikas, a key account FRIDAY, 10:42 AM if this is a pivotal moment or just a bit
manager, saunters casually into the Midwest Regional Headquarters, of a bad patch:'
room. ((Would an order for 40,000 new- Flemings ValuMart
account cases help?"
All eyes turn to Vikas. The phone rings. Alice Oias doesn't rec- FRIDAY, 11 :59 PM
"Who's the account?" Martin asks. ognize the number displayed; it's from Bedroom,
"Regency Brands. It's an overseas trad- somewhere out of state. Residence of R. Foley Vinton
ing company. They sell into Eastern Eu- "Alice Dias!'
rope, }iangsu province in China, and (4Hello, Ms. Dias;' says an unfamiliar Foley Vinton, having turned in early so
other markets where we have no orga- voice. "I represent Regency Brands." as to be fresh for his 7:00 AM tee off, lies
nization or trading reps." "Yes?" she replies politely. l'How may in bed but can't sleep.
uWeird combi nation of territories," I help you?" "Every business has its tight spots and
says the veteran. "I am hoping that I can help you;'says difficult moments," he muses. "It's al-
The word Udiverter" burns into Mar- the voice. "We're in a position to offer an ways a race to close the quarter in this
tin's mind. (' What price did you quote?" attractive case discount on the Exceso industry. A leader cannot capitulate to
he asks, half hoping it will be an offer he ClickZipPlus:' the concerns, however understandable,
can refuse. " I believe I already have the lowest of rus people. He must paint a positive
"Deep discount: 9%. If we receive pay- discount available, direct from the man- picture for them. Exhort them to seek
ment within five days!' ufacturer!' innovative solutions.
Martin doesn't argue. "I think I can beat it!' "And yet, I didn't like the way my con-
UWhat do we know about this com- "Well:' says Alice, "I'm listening." versation with Martin ended. Normally,
pany?" asks the young manager. we can disagree and finish up with a
Vikas inclines his head as if the ques- laugh. This time seemed different. If I
tion were tiresome and possibly irrel- FRIDAY, 11 : 10 AM lose Martin, which is possible, we will
evant. "We know they're willing to sign Small Conference Room, certainly not make our number. He's
the deal in time for it to count for trus McKenna, Palash & Zweig Securities right that we agreed to end the trade
quarter." loading. But he knows we can't change
Silence befalls tbe room. Andrea Valdini reviews ber notes before just like that. It's almost impossible for
"Well," says Martin, at last. "Let's do a meeting with her colleagues at wruch one manufacture r to buck a chronic
our due diligence on them!' they plan to discuss Exceso and other industry practice. We can try, but we
"The offer is only good until eight current holdings. have to try at the right time and in the
tonight;' Vikas replies. "I suppose J can "Exceso is a fundamentally sound rigbt way.
make a few calls about them, but they company:' she thinks. "They're just C/Besides, there are factors that Mar-
smell okay to me!' caught in a little whlrJpool created by tin's not aware of. We'lJ certainly get
('How are they going to pay?" asks the slow retail sales, the lull before a new- board approval for the capital improve-
veteran. product launch, and a sluggish econ- ments to manufacturing. That will help
"Letter of credit. London bank;' says omy. Foley Vinton has an admirable with productivity and, eventually, costs.
Vikas. "That I've already checked out." track record. ClickZipPlus is still the We're ready to push the on-Une sales
Martin Wu looks at the faces of his market leader, even if the competition channel next quarter. That should boost
team members. Forty thousand cases is catching up. Exceso has a strong bal- sales. And, of course, there's the acquisi·
would not make the quarter, but it cer- ance sheet. tion. We're very close on that!'
tainly would help. It would buy time. "So why does that empty product di s- Foley, drowsy at last, lulls himself into
Take some pressure off. play unnerve me so? It's not like I did an a light sleep, Wnking, "If we can just
"We have to decide;' says Vikas. inventory of every retai I outlet in the get over trus hump, we'lJ have a little
('I can hear that old injection molder country. My evidence is anecdotal, at breathing room. Then we can solve this
running right now:' says the veteran. best. If Exceso is loading to make their once and for al l:'
"I trunk the folks in Jiangsu province numbers, why wouldn't tbe displays be
are going to love the ClickZipPlus;' com- full? And if sales are off, why would they Should Exceso maintain its
ments Fred. be running three shifts to manufacture aggressive promotion strategy?
Martin nods almost imperceptibly. product? Their share price hasn't moved Four commentators offer expert advice
Vikas scurries out of the room. Martin at all in the last six months, but they're beginning on page 38.
MAY 2002 39
HBR CASE COMMENTARY· Should Exceso Ma i ntain Its Aggressive Promotion Strategy?
Exceso and Flemings both are sufferingjrom the same basic and
long-standing problem: a lack ojsupply chain visibility.
~
a n executive with Wegmans Food Mar- the essence of the consumer goods industry
kets, I identify with Flemings's busi- initiative known as CPFR (collaborative plan-
ness more than Exceso's. But the situ- ni ng, forecasting, and replenishment), whic h
ation doesn't look much prettier from this my organization helped to pilot. They could
side ofthe fence. Both companies are suffer- cooperate in other ways as wel l. Wal-Mart,
ing from the same basic and long-sta nding known for its supply cha in excellence, rel ies
problem: a lack of supply cha in visib ility. No heavily on vendor-managed inventory. Its
one really knows how mu ch product is being suppl iers use a Wa l-Martsystem cal led Retail
so ld at what price, how much inventory is in Link to check inventory levels, and it is their
the system, o r where exactly it is. responsibi lity to rep lenish thei r products ap-
To make that clear, the two businesses will propriately. At Wegmans, too, we're working
have to colla borate, which will require a on supply chain visibility, envisioning the day
healthy measure of trust between them. But it spans flu idly from demand to consump-
it's d ifficu lt to imagi ne that trust existing, tion - in other words, begi nning and end ing
given that their goals are so mismatched. with the consumer.
Foley's primary goal is to pump up the value All this requires accurate, timely informa-
of his company's stock. Fl emings's and Ex- tion, of course-but that information pays
ceso's customers are focused on extracti ng other dividends, allowing profits to be un-
whatever price concessions th ey can. Where's derstood and managed at the item level.
the consumer in al l this? That's why Alice Dias,despite her formidable
Irs telling that the one glimpse we get of negotiating ski ll s, would never last at Weg-
a consumer in the case shows her frustrated mans. She's not aware of the true cost impli-
by a poorly stocked shelf. Exceso and Flem- cations of her decisions. What is the t rue cost
ings probably don't appreciate how much of moving all that product around the coun-
those empty slots are costing them. Accord- try? If Flemi ngs doesn't know the answer to
ing to one famous study, conducted by the that, it has no idea how much retail revenue
Coca-Cola Retail Council in 1996, the value of it needs to make an acceptable profit. And the
items out of stock at grocery retailers totaled same is true for Exceso. When one of Martin's
Mike Bargmann is a senior 6.5%of sales. That's terrible for the manufac- sa les managers asks how mu ch the margin s
vice president oj distribution tu rer because a consumer's second choice is will suffer from all their promotiona l activity,
at Wegmans Food Markets, usually a competing brand. But it's terrible Martin can only say, "Not sure."
a 6o-store chain based in for the retailer, too, because 3,196 of the time, Greater supply chain visibility wil l give
Rochester, New York. He the study revea led, t he consumer simply Martin and Alice the answers th ey need. It
also leads the company's chose to do without, and the sale was com- will also allow them to collaborate on deals
e·business initiatives. that ultimately benefit them both. But again,
pletely lost. Clearly, both parties stand to gain
significantly from a joint effort to keep items the process has to begin with a new focus
in stock. on the consumer, And that has to start at the
With that basic objective in mind, Exceso top. Foley and his counterpart at Flemings
and Flemings cou ld start by collaborat ing on need to provide that vision and make sure
a business plan for the ClickZipPlus, which that individual incentives are aligned with
would outline shared goa ls for the product it. Thi s industry has a long way to go before
category and their sa les plans on an annua l, such coope ration is the norm, but we've
semiannua l, or quarterly basis. They might made tremendous progress. I look forwa rd
even work together to make the sales fore- to the day whe n this case reads like pure
casts behind that plan more precise, This is ficti on.
H
Ow can a company that knows it accurate assessment of the problem - one
has a problem - and even seems to that's comprehensive enough to uncover all
know the solution to it-be unable those nasty second- and third-order effects
to help itself? I've addressed this question that we readers get to observe in the case.
many t imes with senior management teams. What's the real cost of those empty store
What becomes clear is that before any solu- shelves and the manager's lack of hesitation
t ion can be put in place, awareness of the in steering loyal Exceso customers to com-
problem and commitment to address it have petitors' products? And where are those in-
to occur on four separate levels. ternationa l (wink, wink) shipments really
First, group members have to acknowl- wi nding up? It won't be hard to get the facts
edge that there is a problem. Sou nds si mple, once Exceso's executives put their minds to
even trite, but it's amazing how often people it. What will be hard is putting th ei r minds
with in an organization can refuse to see a to it-transforming people long practiced in
problem that looks blatant to outsiders. Sec- innuendo and collusion into truth see kers.
ond, they must agree that the problem is sig- Foley can sta rt by taking the concerns of
nificant. Th ird, they need to believe that it is others seriously. I n the garage, we see Martin
in their power to fix the situation. And fourth, trying to raise a critical issue and Foley im-
they have to believe that there are th ings they med iately discounting it. Foley simply gives
each can do to bring about the change.Once him a verbal pat on the head and moves on.
Jean;e Daniel Duck is a
we recognize that these four levels of denial In the sales meeting, fundamental questions
senior vice president at the
Boston Consulting Group, exist, it's easy to see how people can blow off and potential solutions are raised on ly to be
in its Atlanta office. She is a prob lem or a potential solution. immed iately swamped by cynicism born of
the author o/The Change There is some consensus at Exceso at the habitual expediency. Martin, too, falls prey
Monster: The Human Forces fi rst level - that a problem exists. But people as he asks for due diligence on the diverter
That Fue I or Foil Corporate disagree over how significant the problem is but then doesn't pus h for it. In a cu lture of
Transformation and Change and whether it can be fixed. Foley believes truth seeking, these conversations would
(Crown Business, 2001). trade loading is cu rrently the so lution to a have developed very differently.
greater problem -making the numbers- and Fol ey won't change his organization unti l
that he can easily transform the situation he welcomes change himself- and it's clear
when the ti me is right. Others (the sales staff. he's not ready. H is form of resista nee reminds
me of members of an execut ive team I once
met who were dealing with a similarly per-
Before anyone at Exceso ever gets serious sistent probl em. When I asked, "What's going
to change this situation?" they offered any
about kicking the trade-loading habit, they'll number of factors: Yen fluctuations cou ld
allfirst have to kick their truth-hedging habit. turn in their favor, their major competitor
cou ld run out of product, the recession could
quickly turn around. The list was long, but, in-
for instance) seem resigned to load ing as a terestingly, none of it was within the ir con-
fact of life. But the two sides won't have the trol. Now, consider Foley's inner dialogue at
cha nce to come together because the prob- the end of the case, when he rattles off a list
lem is not even discussible. Any correction of forces either out of hi s control or not re-
that might have been afloat is dead in the lated to his supply chain problems. When you
water wel l before anyone is forced to con- hearthis kind oftalk, ifs usually a t ip-off that
front that very uncomfortable question of someone is trying not to deal with a problem.
what each persona lly might do differently. My impression is that, even as he's lying in
Before anyone at Exceso ever gets serious bed, this guy is stil l lying. el
about kicking the trade-loading habit, they'll
Reprint R020SA
all first have to kick thei r truth-hedging habit. 10 order reprints, sec the lasl page
Management can begin by conducting an of Executive Summaries.