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Miles Flint, Deputy Managing Director - Western Europe, lenges he and his colleagues faced in realising improve-
paused for effect before delivering his concluding mes- ments in supply chain flexibility, adaptability and res-
sage to the members of his management team attending ponsiveness to market demand.
the Sony Broadcast and Professional Europe “Kick-off
Conference” held at Reading in April, 1997. This event As Flint had remarked earlier,
marked the beginning of the 1997 fiscal year.
For many of our customers, Sony is still too difficult to
When we meet for the 1998 Kick-off Conference in do business with. That was OK when the customer had
about a year’s time, we shall be able to confirm to our- no choice other than to buy from us. It simply will not
selves that the way we are working, and the issues we do in today’s competitive world. As margins are squee-
are challenging, truly reflect BPE’s mission of being a zed, pressures on supply chain performance, inventory
virtual company. A year from now we shall be living reduction and the need to eliminate duplication of
this mission, not just aspiring to it as is the case today. processes and costs will continue to intensify.
Our mission, as we see it, will have become more of a As management, we are in a race to accelerate our
reflection of reality than a statement of intent. capacity to change.
Flint had been a vocal champion and driving force Sony Broadcast and Professional Europe
behind the virtual company concept since its inception.
It encompassed his own strongly held beliefs about how Sony BPE, with headquarters in Basingstoke some 45
Sony Broadcast and Professional Europe (Sony BPE) minutes drive from London’s Heathrow Airport, served
should be structured and managed. His vision was of a markets in 116 countries in Western Europe, Eastern and
number of business teams working across the European Central Europe, the Middle East and Africa. In fiscal 1996
zone rather than in each country. The teams would not it accounted for a commensurate proportion of Sony
operate out of the headquarters - rather, team leaders Corp’s European sales of DM 17.6 billion. It employed
and indeed team members would be geographically dis- some 1500 people operating out of 23 locations, the
persed throughout the zone. Support functions, e.g., majority of which were in Western Europe.
information systems/management, human resources,
supply chain and finance would be organised in such a Sony BPE comprised two major business groups:
way as to provide the necessary infrastructure and sup- Broadcast (BC) and Business & Industrial (B&I).
port for the teams. Broadcast served both state and private radio and TV
stations, production houses and music recording stu-
For Derry Newman, Divisional Director Information dios. The market channel was direct – business-to-busi-
Systems and Supply Chain, Flint’s comments only ness. On the other hand, the Business & Industrial group
underscored the operational opportunities and chal- relied on indirect selling through dealers who handled a
broad range of products, e.g., closed circuit television viders. Vianen, originally built for inter-warehouse ope-
security systems, projectors, camcorders, etc., as well rations, acted as a staging area to serve the 14 national
as specialised equipment for video conferencing, medi- sales company warehouses. Shipments between Vianen
cal and educational applications and giant screen dis- and the NSC warehouses were scheduled on a regular
plays. With the exception of the Nordic countries, which basis. Some warehouses (France, Germany, Italy, Spain
operated regionally, each of the Western European coun- and the UK) were served every 2-3 days, while smaller
tries had their own National Sales Company (NSC) and country operations were served only weekly.
warehousing operations. Procurement was a two-stage process. It was initiated at
the NSC level through the submission of a 7-month rol-
ling forecast of demand by product to the supply chain
The issues we are challenging, administration teams. The monthly forecasts were
truly reflect BPE’s mission based on both historic data and market intelligence,
with equal attention being paid to all products. Given
of being a virtual company the forecasts of demand, replenishment orders were
determined based on on-hand inventory, anticipated
receipts, and a desired target stock level (TSL). The
Sony BPE Supply Chain – April 1997 replenishment cycle was weekly from stock held at
Vianen.
As of April 1997, the vast majority of products sold by
Sony BPE were manufactured in Japan and imported At Basingstoke and Vianen, supply chain administration
into one of two distribution centres. The Basingstoke teams consolidated the forecasts and orders received
distribution centre was dedicated to BC products while from the NSCs to assess projected supply/demand
B&I products were distributed through Sony Logistics balance. In placing monthly orders on the Japanese fac-
Europe’s (SLE) hub at Vianen, The Netherlands, an tory, consideration was given to aggregate demand and
hour’s drive from Schiphol Airport. In terms of BPE the accuracy of the forecasts, on-hand inventory, antici-
stock-keeping units (SKUs), Vianen handled 10 times pated receipts, and a desired TSL. The TSL was to cover
more than Basingstoke. demand both during the manufacturing lead time and
the length of the procurement cycle. It also included
Broadcast products were shipped to Basingstoke by air some safety stock. For B&I products, the TSLs varied
freight, the elapsed time from factory to Basingstoke from 60-90 days. Order-delivery cycles were of 4-5
being typically 5 days. At Basingstoke, the BC products months’ duration depending on the product.
went through a customer-specific configuration and tes-
ting process before being shipped via Vianen for ultima-
te distribution from a NSC warehouse to the customer. In
some instances, products were re-checked and re-confi- As management, we are in a race to
gured at the NSC warehouse before shipment. Transport
from Basingstoke to Vianen took one week. This inclu- accelerate our capacity to change
ded preparation and despatching of the physical goods
together with appropriate shipping documents, alloca-
ting space on a truck making daily deliveries to Vianen,
then receipt and cross-docking procedures on arrival. Opportunities for Virtual Logistics
Only a small percentage of BC products were shipped
directly from Basingstoke to the customer. In January 1997, Derry Newman had commissioned an
internal study of the B&I supply chain with the express
Unfortunately the system was prone to error due to inef- purpose of increasing its flexibility, adaptability and res-
ficiencies in both material and information handling pro- ponsiveness. Newman believed,
cesses, which resulted in partial shipments and late deli- The factory to customer logistics process can be repre-
veries. sented by a ‘virtual warehouse,’ where the majority of
physical activities from factory gate to customer pre-
All B&I products were distributed through SLE at mises can be outsourced to a global logistics vendor(s).
Vianen. Some 83% of B&I products were shipped from The manufacturer should not be concerned with the
Japan by sea. The elapsed time from factory to distribu- physical location of product within the virtual warehou-
tion centre amounted to some 40 days, which included 2 se provided that product is delivered to the customer at
days for container unloading, customs clearance and the agreed time and place thereby meeting an agreed
local delivery. Sony BPE had DM 40 million-worth of and demonstrable service level.
goods on the water at any one time. In those instances
in which air freight was used, the elapsed time was redu- The creation of a “virtual warehouse” would require the
ced to 5 days. re-evaluation of BPE inventory holding policies and the
use of Sony’s SAP system R/3 to integrate suppliers, ven-
SLE undertook all material handling, distribution and dors and internal divisions.
transportation activities. It invoiced the Sony product
divisions accordingly. Transport was provided by a com-
bination of owned vehicles and third party logistics pro-
The report recommended that a significant proportion TNT, Danzas, UPS and Euro Express were four compa-
of B&I products should be shipped by air freight. The nies short-listed by Newman as potential third party
increased cost of air freight would be offset by the bene- logistics providers. In making a final selection, Newman
fits of reducing overall transit time from 40 days to 5 considered the following to be of critical importance.
days. These included:
1. Geographic Reach and Capacity
1. Overall reduction in inventory investment, i.e. safety The preferred supplier would have pan-European opera-
and transit stocks. tions with an ability to provide next day/48-hour service
2. Improved responsiveness. anywhere in Europe at competitive rates. The supplier
3. Reduced planning horizons giving rise to increased should be capable of expanding to match the growth in
forecasting accuracy and potential reduction in slow- Sony BPE volumes and be flexible in meeting changing
moving inventory. market requirements. The supplier would be expected
4. Reduction in space requirements at warehouses. to dedicate full-time resources to the Sony account.
5. Reduced time to market.
6. Increased reliability of air freight versus sea freight. 2. Customer Interface and IT Focus
The Centralisation of Inventory and As the supplier would be Sony’s representative in inter-
Direct Delivery acting with the customer, an ability to project Sony’s
image locally was critical. To this end the supplier
On the basis of a detailed cost analysis, it was recom- should have a local presence rather than sub-contract
mended that BPE products should be distributed direct- to a local carrier. The supplier would also be expected to
ly from Vianen to customers and that the actual delive- commit to and demonstrate a high level of delivery ser-
ries, in most cases, be undertaken by a third party logis- vice. Criteria would include on-time delivery reporting,
tics provider. Tangible savings were to be achieved same-day reporting of proof of delivery and the resolu-
through the elimination of cycle stocks at the NSC ware- tion of non-deliveries within 24 hours. A pan-European
houses and the reduction in the level of safety stocks for tracking system would be essential.
individual products. Such safety stocks proliferated as
the number of national sales company warehouses 3. Rewards and Penalties
increased. Intangible benefits were also cited. These A bonus/penalty system would apply and be based on
included: service levels achieved against targets. In the event of
damage, the service provider would be expected to
1. Increased responsiveness to customer demand. issue a credit note covering the service charge for the
2. Increased levels of customer satisfaction. complete consignment.
3. The opportunity to undertake forecasting on a pan-
European basis and, as a result, improve forecasting Getting Started
accuracy.
4. Facilitation of product life cycle management, Re-engineering the supply chain to support the virtual
particularly at the end of the life cycle where obsoles- company meant that Newman needed to address the
cence risk through overstocking was high. challenges posed by the centralisation of inventory,
5. The holding of inventory at a lower value-added direct delivery and the selection of an appropriate third
position in the supply chain. party logistics provider. How should he go about addres-
sing the concerns of dealers, national sales companies
Additionally, it was shown under what conditions the and BPE employees in order to ensure that the “virtual
costs of a third party logistics provider would be less warehouse” might be realised? Newman was also
than the combined transportation and handling costs if conscious of the imperative to safeguard Sony’s reputa-
products were shipped from Vianen to the customer via tion for customer care and thereby its brand image.
the NSC warehouse. Under the circumstances, was the timing of the change
to the centralisation of inventory and direct delivery too
ambitious?
However, each of these advan- Sustainable improvement – If these four aspects of the change
tages has disadvantages associated making it work programme are implemented well,
with it. An approach that has delivered the organisation can change its
successful outcomes at many of behaviour, and the desired results
At a strategic level, a disadvantage Celerant’s clients could also be the – better customer service, greater
lies in the time needed to set up a route to success for Sony BPE. It is flexibility, and reduced costs – can
coordinated effort between Sony based on the philosophy that sus- be achieved for Sony BPE within
and its partner(s). Moreover, Sony tainable results can only be achie- the allowed timespan of a year.
may not gain real insight into the ved by changing the way the orga-
performance of its partner(s) for nisation behaves. And to achieve In taking on the challenge, howe-
some time. With a partner presen- this behavioural change, work is ver, management at every level
ting the ‘face of Sony’ to custo- needed on four aspects of the needs to be fully committed to
mers, lower quality levels at deli- organisation: the processes, the supporting the organisation as it
very will damage Sony’s image. systems, the people and the infor- introduces the agreed changes
mation technology (IT). while maintaining ‘business as
At an operational level, Sony may usual’. New capabilities may need
be disadvantaged by becoming to be brought in to the organisa-
Sony needs to understand how its
dependent on a third party. What tion (e.g. IT or project manage-
new logistic process will function.
happens if the partner does not ment skills). Communications with
That means mapping out the new
abide by the contractual agree- employees, partners, and other
process, and the other processes it
ment? stakeholders (such as unions and
will affect, and communicating
and validating these mappings customs) will require considerable
From a financial point of view, and consistent attention and
there are extra costs involved in throughout the whole organisa-
tion. It is important that everyone effort. As a result, there should be
creating the kind of coordination an acceptance that costs may rise
needed to make the partnership(s) has the same vision.
during implementation. And a
work. Extra costs may arise if a
Systems are needed to continuous- reliable and committed partner
decision is taken to change part-
ly support the logistics process. will be important to support the
ner, or if a partner does not live up
With the help of business perfor- change process through the tight
to the required standards.
mance indicators, appropriate schedule envisaged.
An additional, and not insignifi- management systems will enable
cant, set of costs can be incurred in the measurement and manage- Conclusion
making employees redundant ment of process efficiency, as well
when a virtual warehouse is set as ensuring clarity about who is The Sony case provides a clear
up. It may be possible to reach an responsible for what. Possible example of the ‘virtual warehouse’
agreement with the logistics part- indicators in the Sony case could approach to supply chain manage-
ner, such that the Sony employees be customer satisfaction, OTIF deli- ment. More and more companies
affected become part of the part- veries, required lead-time, trans- are doing exactly what Sony did:
ner’s workforce; but this is not a port time, stock costs, and so on. going back to their core business
given. and questioning their secondary
People are usually the key to suc- activities. In terms of Porter’s
Taking into consideration the cess for a change project such as value chain, companies are focu-
advantages and disadvantages of this. Therefore extra attention sing on their primary processes
the virtual warehouse solution, should be giving to making people and seeking partners for the
several other questions need to be aware of the need for change at secondary processes who can pro-
addressed: Who carries the res- Sony, and coaching them to work vide added value.
ponsibility for the Sony product in the new environment. New
during handling by a partner? opportunities should be created, IT outsourcing has been around
How will the partner be assessed so that people can see a ‘win-win’ for a long time and has yielded
in terms of customer satisfaction? situation ahead. If people have to mixed results. ‘Logistics outsour-
What if something happens to the be let go, e.g. those working at cing’ is another way of looking for
customer, e.g. financially? Is there the national sales companies, then added value, gaining popularity.
a fall-back position? personal support services such as Whatever the challenge, manage-
outplacement must be provided. ment should make a sound study
Clearly, there is much more invol- of the wide-ranging options open
ved in setting up a ‘virtual’ ware- IT is an essential ingredient in to the company, and look out for
house than first meets the eye. ensuring the virtual warehouse all the possible advantages and
Management needs to understand concept can work. Several disadvantages. Once a solution
all the implications of its chosen changes will be entailed: in the has been reached, the two prere-
solution, both positive and negati- communication between the sales quisites for successful implementa-
ve. At the very least, if the virtual organisations, the warehouse and tion are a detailed and realistic
warehouse plan is to proceed, a the production locations; and also plan, and full management com-
sound service level agreement is in the interfaces with the logistics mitment.
required; and a solid project partner(s), customs and other
management approach needs to external players.
be implemented at Sony.