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ALI RAZA----------------------------------------1390
AYESHA CURMALLY--------------------------1188
SYED SABIH AHMED-------------------------1303
SHOMAILA MALLICK-------------------------1185
FAIZAN SHEIKH--------------------------------1309
ACKNOWLEDGEMENTS
In lasts but of course not the least We show homage and all gratitude to
our honorable teacher MR. RANA MUHAMMED IDREES, who supported us
and shared his great professional experience and knowledge with us and
the management of ICI for sharing very comprehensive information about
their production and transportation from raw material to finished goods
and whole process of supply chian.
DATED: 10-MAY-2010
TABLE OF CONTENT
ICE’S VISION--------------------------------------------------------------------------------------
1
ICI GROUP IN BRIEF------------------------------------------------------------------------------
1
INTRODUCTION-----------------------------------------------------------------------------
-3
COMPETIVE AND SUPPLY CHAIN STRATEGIES---------------------------------------------------5
AN INTRODUCTION TO SUPPLY CHAIN MANAGEMENT ---------------------------------------6
DIRVERS AND SUPPLY CHAIN
PERFORMANCE---------------------------------------6
MODE OF TRANSPORTATION ------------------------------------------------------------------8
SUPPLY CHAIN DECISIONS------------------------------------------------------------------ 10
DESIGNING DISTRIBUTION NETWORK IN A SUPPLY CHAIN NETWORK------------------ 10
SUPPLY CHAIN MODELING APPROACHES------------------------------------------------ 12
CREATING VALUE BY ALIGNING SUPPLY CHAIN----------------------------- 13
EFFICIENT CONSUMER RESPONSE (ECR) ----------------------------------------------- 13
PLANNING DEMAND AND SUPPLY IN SUPPLY CHAIN-------------------------------------- 15
SYNCHRONIZATION OF PRODUCTION TO CONSUMER DEMAND------------------------ 15
DEMAND AND SUPPLY CHAIN SYNCHRONIZATION-------------------------------------- 16
DEMAND FLOW MANAGEMENT-------------------------------------------------------------- 16
SUPPLY FLOW MANAGEMENT--------------------------------------------------------------- 17
AGGREGATE PLANNING IN SUPPLY CHAIN------------------------------------------------- 19
PLANNING AND MANAGING INVENTORIES-------------------------------------------------- 21
MANUFACTURER------------------------------------------------------------------------------ 21
PRODUCTION DECISIONS ------------------------------------------------------------------- 22
INVENTORY DECISIONS ---------------------------------------------------------------------- 23
PRODUCT AND PROCESS INNOVATION----------------------------------------------------- 24
CREATING CUSTOMER VALUE BY ALIGNED PACKAGING SUPPLY CHAIN OPERATIONS------- 24
PACKAGING SUPPLY CHAIN BENEFITS---------------------------------------------------- 25
SOURCING TRANSPORTING AND PRICING PRODUCTS------------------------------------ 26
LOCATION DECISIONS ----------------------------------------------------------------------- 26
TRANSPORTATION DECISIONS-------------------------------------------------------------- 27
INFORMATION TECHNOLOGY AND SUPPLY CHAIN---------------------------------------- 27
ELECTRONIC DATA INTERCHANGE--------------------------------------------------------- 27
MASTER DATA MESSAGES------------------------------------------------------------------ 28
COMMERCIAL TRANSACTIONS MESSAGES----------------------------------------------- 28
REPORT AND PLANNING MESSAGES------------------------------------------------------ 29
BENEFITS OF ICI SYSTEM APPLICATION-------------------------------------------------- 29
E-BUSINESS AND SUPPLY CHAIN BUSINESS PROCESS REENGINEERING------------- ----------30
E-BUSINESS IMPLEMENTATION------------------------------------------------------------- 30
BUSINESS PROCESS AUTOMATION-------------------------------------------------------- 31
STANDARDIZATION--------------------------------------------------------------------------- 31
KEY BENEFITS OF ICI SYSTEM APPLICATION-------------------------------------------- 32
FORWARD-LOOKING STATEMENTS--------------------------------------------------------- 33
BIBLIOGRAPHY--------------------------------------------------------------------------------
34
ICI’S VISION
AkzoNobel is the largest global paints and coatings company and a major
producer of specialty chemicals. It is a Fortune 500 company, and is listed on the
Euronext Amsterdam stock exchange as well as being included on the
FTSE4Good Index, and is also a leading company in the Chemicals Industry
sector on the Dow Jones Sustainability Indexes.
• We are one of the largest quoted companies on the Karachi, Lahore and
Islamabad Stock Exchanges
• We have a paid up share capital of Rs 1.39 billion.
• Our turnover in 2008 was Rs 31.92 billion and profit before tax crossed Rs
3.13 billion.
• Our company employs around 1300 permanent staff members.
Our five businesses, Polyester, Soda Ash, Paints, Chemicals and Life
Sciences, manufacture and sell a wide range of industrial and consumer
products. These include:
A bit of history
ICI Pakistan Limited was set up as a public limited company in Pakistan in 1952.
However, ICI was an active presence in this part of the world well before the
formation of the public limited company and indeed, even before Pakistan itself
was created.
1944
The Khewra Soda Ash Company, a predecessor of ICI Pakistan Limited, set up a
soda ash manufacturing facility in Khewra with a capacity of 18,000 tonnes per
annum. This facility was sited next to the salt range as rock salt and limestone,
two key raw materials needed for manufacturing soda ash, were available here
in abundance.
1953
The Khewra Soda Ash company was incorporated as a public limited company.
1966
The Khewra Soda Ash Company changed its name to ICI Pakistan Manufacturers
Limited.
Over the next few decades, major changes took place in the company as our
Specialty Chemicals and Polyester plants were commissioned, and Imperial
Chemical Industries (Pakistan) Private Limited and Paintex Limited both merged
into ICI Pakistan Manufacturers Limited.
1987
We changed our name to ICI Pakistan Limited
We also established ICI Pakistan PowerGen and set up the ICI Pakistan
Foundation as a charitable trust.
1995
We set up a USD 490 million PTA manufacturing facility at Port Qasim, near
Karachi.
1998
PTA manufacturing facility commissioned.
2000
The business was de-merged to form Pakistan PTA Limited, which was at the
time a subsidiary of ICI Plc UK.
2007
We completed 50 years of continuous listing on the Karachi Stock Exchange.
2008
We formally became part of the AkzoNobel Group, bringing us under the banner
of one of the largest coatings and chemicals companies in the world
About Polyester
Weaving our way forward
We manufacture and market Polyester Staple Fibre (PSF) , a man made fibre and
a key substitute and complement for cotton. In a textile intensive country like
Pakistan, it is a highly critical raw material that is spun into yarn, which is then
woven or knitted into fabric used to make shirts, shalwar kameez, bed sheets
etc. that each one of us uses.
It is hard to comprehend thus that this fibre, which so closely resembles cotton
in its applications, is not grown in the fields but is a part of the petrochemicals
chain, and the shirt that you wear has actually been derived from crude oil!
We introduced this wonderful product to this country as far back as the early
80’s. As pioneers of the polyester staple fibre technology in Pakistan, we
enabled the cotton rich textile industry to diversify their products and be more
competitive in the international arena where the growth of man made fibres has
been phenomenal.
About Paints
Coloring Pakistan for 44 years
We know from years of experience that our customers expect nothing short of
the best from us. Delivering results is a part of our DNA; it’s how we do business.
And so, we launch innovative products, train our teams, continuously improve
our processes, and invest in research to make sure our customers have access
to a wide range of high quality products, paint solutions and services.
In Pakistan, the latest surveys indicate that 97 out of 100 people know who we
are! Our huge distribution setup across the country makes sure our products are
available to all these potential customers.
Of course, we now have an added advantage; the world’s largest decorative and
performance coatings company is backing us. With AkzoNobel and its global
reach and expertise, we have lots of exciting opportunities for growth and to
enter new fields.
Put together, all of this makes us the leading paints company in Pakistan.
We are market leaders for this key ingredient in the manufacture of glass, paper
and detergents. Soda ash is an essential commodity and we’re proud to be the
largest producers of it in the country.
Our Soda Ash Plant in Khewra was established in the 1940s, even before the
creation of Pakistan! Since then, we have seen tremendous growth; we currently
have an annual production of 350,000 tons. Our plant is the largest of its kind in
Pakistan.
Our business is diverse and we are proud of the important role we play in
helping to enhance lives; for example, we market some of the leading
pharmaceutical brands today such as drugs to fight life-threatening diseases like
cancer.
Because of this, we are even more committed to innovation and keeping ahead
of the curve with products and services that draw on the newest research and
latest advances. We want to make sure our customers trust in us remains solid
and that our brands remain synonymous with quality and consumer confidence.
About Chemicals
Turning the wheels of industry
We’re not stretching the truth when we say we service practically every industry
in the country! Our products are essential in all kinds of manufacturing
processes and in products from adhesives to paint, and from insulation for
housing and refrigeration to textile auxiliaries that determine the finish of fabrics
we use.
We enjoy the benefit of global insights, and knowledge amassed from a long
history of serving our customers’ needs. We don’t just manufacture and market
essential ingredients for today’s demanding industrial world, we also offer
technical solutions, and we’ve begun exporting into the region.
Where chemicals are involved, we know we have to be extra careful about our
impact on people and the world around us. Our strong emphasis on health,
safety, and environment means we incorporate the best practices from around
the world, providing full safety information to customers, a safe workplace for
employees, and care for the environment through many of our projects focusing
on sustainability
OUR BRANDS: -
Dulux
Dulux is a renowned brand the world over, and here in Pakistan it’s no
exception.
Wherever you travel in the country, you are likely to see our premium paint
brand at work beautifying and protecting people’s homes and workplaces.
As a brand Dulux has been known and trusted for generations. We are proud of
that, and work hard to ensure not only that we give our consumers the same top
quality products they have grown to rely on, but also that we keep innovating to
create new products for the ever-evolving paint market.
Whatever your paint needs, we’re sure you will find something in our Dulux
range to give you the results you want.
International
International Paint is part of AkzoNobel, the world’s largest coatings supplier.
Our unrivalled investment in product development leads us to provide you with
high quality protective coating products.
When uncoated carbon steel structures come into contact with the environment,
the usual result is corrosion. Protective coatings are essentially designed to help
prevent and seriously slow down the corrosion process. In addition, protective
coatings can also be used to provide passive fire protection for structural steel.
Paintex
We all want the best quality but we also want it at a reasonable price.
Paintex, our mid-tier paint brand, provides you with an opportunity to enjoy the
finer things in life while still spending your money sensibly. Paintex gives you a
complete range of exciting color and high quality finishes for all your
requirements, at an affordable price that lets you enjoy color without worrying
about costs.
• Paintex Emulsion
• Paintex Hi-Gloss
• Paintex Putty
Sikkens
Sikkens, a world-reknowned brand, is now available across Pakistan.
At Sikkens it all starts with ideas. We use innovative R&D to produce our range
of professional coating systems. Then we make them to the highest standards.
And if customers have something specific in mind, they can always call on our
experts for personal support.
High performance, low maintenance; our products will do everything you need
them to. Plus they’re long-lasting and easy to maintain.
We now supply premium Sikkens refinish products for the automobile industry
to the best dealerships and garages across Pakistan.
Terylene
Weaving our way ahead with Terylene, our synthetic Polyester Staple
Fiber (PSF) brand.
FACILITIES
ICI uses facilities decision s to be more responsiveness to their
customers. ICI has an end goal of opening manufacturing facilities in every
major market that they enter. While there are other benefits to opening
local facilities such as protection from currency fluctuation and trade
barriers, the increase in responsiveness plays a large role in ICI’s decision
to locate in their local market.
INVENTORIES
ICI’s competitive targets upper-end customers with high
responsiveness requirements. These customers are willing to pay a
premium to have the products they want when they want them. To
support this competitive strategy. ICI uses inventory the industry stocks a
large variety and quantity of products to ensure a high level of availability.
In fact ICI stocks a significantly larger amount of inventory. It incurs higher
costs because of their large inventory but they gain extra margin fro their
customers.
TRANSPORTATION
IDENTIFICATION OF LOCATIONS
Locations are identified by ICI Global Location Numbers (GLN).
Location numbers are a key concept in supply chain management. A
location number is a numeric code that identifies any legal, functional or
physical entity within a business or organization. Each location is allocated
a unique number. The identification of locations is required to enable an
efficient flow of goods and information between partners through EDI
messages to identify the parties involved in a transaction (e.g. buyer,
supplier, place of delivery, place of departure).
• Combined with EDI, the SSCC provides a link between the information flow
and the physical flow of goods
MODE OF TRANSPORTATION
There are six ways to move products produce by: air, truck, rail, ship,
pipeline and electronic transportation. The farm or market location largely
determines which modes of transportation are available. The buyer usually
selects the type of transportation and pays for it directly. In some cases,
you might pay the transportation cost and include it in the final product
selling price.
AIR
Airlines are used exclusively to ship a few high-value and extremely
perishable products to domestic and export markets. Air freight accounts
for no more than 10 percent of all chemical shipped from the Pacific
Northwest. It is the most expensive mode of transportation.
TRUCK
The most widely used means of transporting paints is truck trailer. This
method has grown in importance as the national highway system has
expanded. Products can be shipped by truck from any growing area to any
market in the costal areas around the world.Transportation by truck
usually is more expensive than by rail or ship but less expensive than by
air.
RAIL
Five percent or less of all produce shipments are by rail. Rail service is
used primarily. Destinations usually are major eastern cities.
Full carloads almost always are necessary. Product groups move large
volumes into large markets on a steady basis. Trailer-on-flat-car service is
increasing, while straight railcar service is declining.The shipper or the
buyer books directly with the originating railroad company. The railroad
assigns a nearby loading facility and handles the billing.
SHIP
Total worldwide shipments by sea account for 50 percent or greater of
the chemical transported. Refrigerated containers and each unit has its
own electric refrigeration unit powered by the ship's engines. Some
containers can use modified atmosphere to protect produce better. Dry
containers often are used for long-lived.
ELECTRONIC TRANSPORTATION
All the orders are received by fax, telephone and on the internet and
payments are received from banks of the world within the industry.
PIPELINE
INFORMATION
ICI is a major manufacturing of chemical worldwide and invested in
an information system that enables them to rapidly get customized
products to the market. This system allows distribution and customers to
actually design windows to custom-fit their needs. Users can place the
order and can get price quotes and automatically sends the order to the
factory if the customers decide to buy.
It is the critical link between the chain’s supply and demand sides:
• From the demand side, the distribution centre must meet all customer
specific requirements with maximum responsiveness;
• From the supplier’s viewpoint, it focuses on efficient handling, inventory
management, product flow, transportation and delivery.
ICI’S STRATEGY:
DIFFERENTIATED RESOURCE ALLOCATION
Maintain
Grow
Strategic Approach
MANUFACTURER
Automated store ordering relies on the ICI System to record product
movement (inventory) and automatically generate a store order. The
order is sent electronically to the distribution centre. A similar ordering
process is repeated between the product manufacturer and his supplier of
packaging materials, and between the packaging company and its own
suppliers. The companies that have adopted this best practice benefit
through lower inventories and higher product availability allowing for more
accurate synchronized production forecasting, planning and execution.
The ICI System enables suppliers of packaging materials and their
customers to share information that allows both to exercise judgment on
the quantities and timing of deliveries and production. Responsibility for
the management and ownership of inventory is agreed upon between
trading partners. “Vendor managed inventory” requires more knowledge
and total control over the logistical processes involved. It enables
suppliers to make better decisions on how to replenish customers’
warehouses with the input of necessary product movement information
from their customers. The concept of self-billing is also enabled by ICI
standards. In essence, it allows the customer to pay for the actual goods
received. The price, delivery and payment terms are previously agreed on
between the trading partners. Self billing is often applied in tandem with
vendor managed inventory.
The reason for using these concepts is to ensure that materials are
Total variable costs
RAW MATERIALS
Petrochemical ~40%
E,g vinyl acetate monomer
Ethylene oxide
Acrylic monomers
Resins/solves
PRODUCTION DECISIONS
The strategic decisions include what products to produce, and which
plants to produce them in, allocation of suppliers to plants, plants to DC's,
and DC's to customer markets. As before, these decisions have a big
impact on the revenues, costs and customer service levels of the firm.
These decisions assume the existence of the facilities, but determine the
exact path(s) through which a product flows to and from these facilities.
Another critical issue is the capacity of the manufacturing facilities--and
this largely depends the degree of vertical integration within the firm.
Operational decisions focus on detailed production scheduling. These
decisions include the construction of the master production schedules,
scheduling production on machines, and equipment maintenance. Other
considerations include workload balancing, and quality control measures
at a production facility.
INVENTORY DECISIONS
PRODUCT STEWARDSHIP
Commitment to product stewardship is one of the core elements of
ICI’s Responsible Care Management System. This encompasses protecting
our customers and the public by the assessment and management of
potential risk from our products throughout their life cycle: research and
development, raw material sourcing, manufacture, storage, distribution,
meet the needs of packaging material suppliers’ operations and not the
needs of their customers. The key to building cost-effective tailored
logistics services is to satisfy different customer requirements by applying
the same global multi-industry standards. For these packaging companies,
which do not use global business standards, providing customized services
could result in additional cost to serve their customers. Any company
could easily end-up investing in several different bar coding and
information systems in an effort to satisfy various identification and
communication requirements by its customers.
For most customers the additional cost cannot be recovered from the
margins associated with them. Aligning internal logistics operations with
customer logistics by means of ICI standards enables packaging
companies to satisfy the variability in services their customers require. As
well as their own internal needs, such as to improve the return on assets
and funds employed on logistic activities. By deciding to implement ICI
standards, companies are able to cost-effectively develop logistics
operations that are aligned to their customer requirements. This provides
a new competitive advantage for packaging companies that are able to
convert their logistics strategy from complexity reduction and cost-
efficiencies to revenue and margin enhancement. Preferred supplier status
and increased margins are the rewards that await suppliers of packaging
materials that master the alignment of the supply chain.
LOCATION DECISIONS
The geographic placement of production facilities, stocking points,
and sourcing points is the natural first step in creating a supply chain. The
location of facilities involves a commitment of resources to a long-term
plan. Once the size, number, and location of these are determined, so are
the possible paths by which the product flows through to the final
customer. These decisions are of great significance to a firm since they
represent the basic strategy for accessing customer markets, and will
have a considerable impact on revenue, cost, and level of service. These
TRANSPORTATION DECISIONS
The mode choice aspect of these decisions is the more strategic
ones. These are closely linked to the inventory decisions, since the best
choice of mode is often found by trading-off the cost of using the
particular mode of transport with the indirect cost of inventory associated
with that mode. While air shipments may be fast, reliable, and warrant
lesser safety stocks, they are expensive. Meanwhile shipping by sea or rail
may be much cheaper, but they necessitate holding relatively large
amounts of inventory to buffer against the inherent uncertainty associated
with them. Therefore customer service levels and geographic location play
vital roles in such decisions. Since transportation is more than 30 percent
of the logistics costs, operating efficiently makes good economic sense.
Shipment sizes (consolidated bulk shipments versus Lot-for-Lot), routing
and scheduling of equipment are key in effective management of the
firm's transport strategy.
• Data Alignment
E-BUSINESS IMPLEMENTATION
ICI decided to form strategic business alliances for long term
contractual co-operation with its packaging suppliers. It demanded
delivery of quality materials from controlled (ISO certified) production
processes, switched price agreements to product lines and embarked on a
partner selection based on quality, reliability, flexibility, and cost criteria.It
would communicate to them its production requirements, such as the
quality, quantity and timing of deliveries of packaging materials. This was
translated into delivery, production, and information windows, as
illustrated in table below. The selected packaging suppliers had to be
ready to progress to e-business by being ICI System competent. The
chosen communication technology was EDI - because of the speed and
security of communication, as well as allowing for a standard interface
between IT applications by means of ICI messages. Another requirement
was the ability to provide accurate and timely product movement data
and implement the concept of self-billing. Therefore, trade item
numbering and bar coding was another pre-requisite.
BUSINESS PROCESS AUTOMATION
STANDARDIZATION
Once this system was operational, a number of customers requested
the addition of further bar coded information to the pallet labels on loads
delivered to their factories, so that they could record the pallets
automatically into their computerized warehouse stock control systems.
Each of these customers required different information to be added to
their labels and used a variety of bar code symbologies. Because the label
printing system was written in-house, including the control of the printers,
it was possible to accommodate these disparate requirements, but it did
complicate the software involved. To cater for the requirement an area of
the label was reserved for this information. Because of the potential
nightmare scenario where every customer would eventually request a
special unique label and the benefits of using a standard packaging label
became quite clear. Packaging saw that the ICI Logistics Label, apart
from being a global standard, provided a number of other advantages. The
use of bar code increased the readability of the label in less friendly
environments. The use of a range of ICI Application Identifiers provided
the flexibility needed to cater for variability in customer requirements
without necessarily prejudicing the standard. The Serial Shipping
Container Code (SSCC) provided a facility for the automatic traceability of
loads.
Because SMI has proved to be efficient, the two companies now plan to set
up the same kind of collaboration with other trading partners. Migration to
the daily flow is their other objective. It will surely be the year of SMI roll-
out throughout our factories and with strategic suppliers.
FORWARD-LOOKING STATEMENTS
BIBLIOGRAPHY
BOOKS:
SUPPLY CHAIN MANGEMENT
By:
BURT, DOBLER, STARLING
WEBSITES:
http://en.wikipedia.org/wiki/ICI_Pakistan
http://www.akzonobel.com/pk