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Supply Chain Management: After Business Process Re-Engineering
Supply Chain Management: After Business Process Re-Engineering
International Scholarly and Scientific Research & Innovation 3(5) 2009 411 ISNI:0000000091950263
World Academy of Science, Engineering and Technology
International Journal of Industrial and Systems Engineering
Vol:3, No:5, 2009
requirements and judges their performance by visiting the continuous improvement; Improvement in Documentation Level in
supplier’s plant site and reviewing the supplier’s quality ISO 9001:2000 based on Quality Management, Department
systems. The Quality Management Systems such as ISO 9000, Procedure, and SOP (Standard Operation Procedure).
TL 9000, QS 9000, ISO/TS 1649, and AS 9100 is to document
and recorded the organizational policies, procedures, work Before BPR, MTB produce Hicom Perkasa only 30 units
instruction and general form. per day. But after restructuring, the output is double to IMM
The statement above is argue by Xu and Lim [9] stated that system. There is less manpower to produce 56 units per day.
in order to achieve supply chain goals and fulfilling customer With production increment, IHM decides to push the dealer
orders faster and more efficiency than competitors, a supply which is Automotive Corporation (Malaysia) Sdn Bhd (ACM)
chain needs competitors, a supply chain needs continuous to sell the product. For continuous improvement, there are
improvement. The items of improvement in performance incentives for production worker based on target achievement
measurement are total cost, distribution cost, manufacturing structure which has been made according to their job
cost, inventory cost and return on investment. Then, for output description.
measure include sales, profit on time delivery customer Why re-engineering? Isuzu Motor Japan sees the potential
response time, manufacturing lead time and customer of Malaysia to become commercial vehicle base and can
complaints. distribute the commercial vehicle at Southeast Asia. The
capacity of Isuzu Factory in Thailand is limited and decided
III. CASE STUDY that Thailand only produce pick up truck for global need.
International Scholarly and Scientific Research & Innovation 3(5) 2009 412 ISNI:0000000091950263
World Academy of Science, Engineering and Technology
International Journal of Industrial and Systems Engineering
Vol:3, No:5, 2009
without any difficulty in the long term period due to the need ii. Service
of marketplace for IHM’s product. Service by vendor should consist of communication,
responsiveness to problems, and availability for field
TABLE 3: assistance. For example, rating should be a collaboration of all
SUPPLIER REQUIREMENT FOR IHM PRODUCT PURCHASE employees in a department who have contacts with vendors.
This include such as activities as calls regarding incoming
Characteristic Low-Cost Response Strategy Differentiation
strategy Strategy
shipments and/or vendor services, availability for training,
1. Supplier’s Supply Respond quickly to Jointly develop direct involvement in problem solving, etc. For example, if
goal demand at changing requirement products and there are any quality or delivery problems, vendor must come
lower cost and demand to option
minimize stock outs
over to communicate with IHM’s to solve the problems. The
2. Primary Select Select primary for Select primary for conversation with buyer is also need to be as frequent as
selection primary for capacity, speed, and product possible. This is to prevent any misunderstanding about the
criteria cost flexibility development skills
Process Maintain Invest in excess Use modular
delivery and also prices towards vendor.
characteristic high capacity and flexible process for
average process preparation to mass iii. Delivery
utilization customization
Based on vendor evaluation, delivery is the major issue in
3. Lead-time Shorten lead Invest aggressively to Invest aggressively
characteristic time reduce production to reduce vendor performance. From 67 vendors for local part sections
lead time development lead at IHM, there are a few vendors that have critical delivery
time problem which means late supply of parts to IHM for running
4. Product Minimize Use designs that Use modular
design performance leads to low setup design to postpone the production. Problem vendor is based on the midyear and
Open Science Index, Industrial and Systems Engineering Vol:3, No:5, 2009 waset.org/Publication/565
International Scholarly and Scientific Research & Innovation 3(5) 2009 413 ISNI:0000000091950263
World Academy of Science, Engineering and Technology
International Journal of Industrial and Systems Engineering
Vol:3, No:5, 2009
International Scholarly and Scientific Research & Innovation 3(5) 2009 414 ISNI:0000000091950263
World Academy of Science, Engineering and Technology
International Journal of Industrial and Systems Engineering
Vol:3, No:5, 2009
training about the important of logistic and production early payment that is about 80 days. Vendor ABC will have
planning management. the opportunity to improve financial management. Vendor
ABC can also request IHM to continue early payment until
iii. Manpower further notice to cover the outstanding raw material from
Shortage, shortage of manpower in welding operation supplier.
and shortage of manpower in assembly. expertise, lack of
expertise and experience to running and maintenance the E. Outsourcing
machine for production and lack of expertise to implement Outsourcing means if there any vendor going to be
new tools and techniques for production such as production eliminated, IHM will have an action to find new vendor to
planning and scheduling. Overtime, no worker desire to work replace the existing problems vendor. For example, vendor
overtime if any shortage of part complaint by IHM, no worker ABC needs to be eliminated because there are a lot of problem
desire to overtime if there have additional order request by such as delivery problem in supplying automotive part. All
IHM and worker cannot work long hour (overtime) during countermeasures done by IHM doesn’t work anymore. Hence,
fasting month. localization program is one of procedure used in selecting a
Countermeasure action: IHM introduce contract new proper vendor as a replacement for the existing vendor.
manpower to vendor at premium cost. Therefore, two shift of IHM will determine the new vendor in two months time before
working period can be done with no problem. The hiring of eliminating vendor ABC.
contract worker is considered as premium manufacturing cost PVD will decide the new vendor to supply those part
by IHM. Vendor ABC might reward and gives incentive to based on vendor performance evaluation sheet. PVD program
worker who did overtime at least 3 hours per day. They also is one of the processes to help IHM to identify what kind of
Open Science Index, Industrial and Systems Engineering Vol:3, No:5, 2009 waset.org/Publication/565
can provide training on new machine and introduce tools and improvement can be developed in SCM. PVD consist three
techniques to run production process such as production consideration items which is Localization program, Product
planning and control, for example. Development and Vendor Monitoring. PVD team consists of
qualified executive with technical knowledge from different
iv. Machine department at IHM which is production planning and control,
Capacity, not enough capacity to do stamping process, Procurement, and Production Engineering department.
only few 250 T machine available (stamping machine), 250 T If there are any suitable vendor for replacement, PVD will
machine available can’t support the requirement and demand study the company background whether they have any
of IHM parts. Schedule, the production process not follow the delivery, quality and services problems with their customers.
schedule done by top management, inappropriate schedule As a result, vendor ABC will be eliminated, and PVD team
orientation in line process, and machine loading schedule due will appoint new vendor such as Vendor XYZ, for example.
to effected part to run on a single machine. die & jig The process is complex and sometimes required a long time.
inspection, less maintenance and inspection done to machine, PVD will try to identify multiple suppliers rather than single or
frequently faced of machine shut down and oldest and need to sole supplier to avoid supplier constraints.
be replace to new one.
Countermeasure action: IHM and vendor ABC decide 3 F. SCM Enhancement
options for improvement which is transferring die to other After BPR, IHM become more confident to survive with
vendor and discuss the drawing and process flow confirmation new challenge with the purpose of spearheading the
with other vendor. Second option is outsourcing to other three commercial vehicle manufacturing and assembling industry in
vendors that do same operation as vendor ABC or buy the 250 Malaysia. There is a little change on management done in
T machine. But if there is no manpower to run the machine, order to increase the productivity. To successfully implement a
IHM will introduce contract manpower to vendor ABC. They supply chain management, IHM is committed to redesign the
need to replace the oldest machine to 200 T capacity machine existing business and production process. Streamlining and
(need additional man/hours) and do second shift operation for improving business and production process should be a crucial
the new machine. These three options need to be decided for part of management’s strategy for improving business
long term delivery improvement. IHM will send their performance.
manpower or technician to repair if the broken machine.
i. E-Procurement
v. Money (financial) One must adopt new technologies and tools such as
Unable to buy material, can cause late receive of raw information technology to control the inventory and
material purchase for production and cash tight to pay supplier outsourcing. E-procurement is used to improve the SCM at
purchase part & old outstanding for raw material. Unable to IHM. E-procurement uses the internet to facilitate purchasing.
pay subcontractor, payment problem by vendor ABC to E-procurement speeds purchasing, reduces costs, integrates the
subcontractor for stamping the material until finished part. supply chain, and enhances an organization’s competitive
Countermeasure action: IHM buy the raw material and advantage. The traditional supply chain at IHM is full of paper
supply to vendor ABC and at the same time IHM pays vendor transactions such as purchase order, request for bids, bid
ABC in advance. For example, the actual payment to vendor is evaluations, purchase order, order release, receiving
90 day per order but in order to help them, IHM will make an documents, invoices and the issuance of checks. E-
International Scholarly and Scientific Research & Innovation 3(5) 2009 415 ISNI:0000000091950263
World Academy of Science, Engineering and Technology
International Journal of Industrial and Systems Engineering
Vol:3, No:5, 2009
procurement reduces this barrage of paperwork. In truth, few [5]. Lee E. K., Ha S. and Kim S. K. (2001). “Supplier Selection and
vendors even come close to understanding the breadth of Management System Considering Relationships in Supply
requirements that any procurement system must satisfy. Chain Management.” IEEE Transactions on Engineering
Management. Vol. 48, no. 3, pp. 307-318.
Nevertheless, they were all scrambling to identify what parts of
[6]. Udomleartprasert, P. and Jungthirapanich, C. (2004). “The
today's procurement processes are tractable and amenable to Supportive Infrastructures Enhancing the Supply Chain
their specific internet capabilities. Performance”. International Engineering Management
Conference. pp. 1204-1207.
ii. RFQs [7]. Svensson G.(2004). “Supplier Segmentation in The Automotive
When purchasing requirement are nonstandard, the time Industry : A Dyadic Approach of a Managerial Model”.
spent in preparing request for quotes (RFQs) and the related International Journal of Physical Distribution & Logistics
bid package can be substantial. Consequently, e-procurement Management. Vol. 34 No.1, pp.12-38.
has now moved these often expensive parts of the purchasing [8]. Summers D. C. S. (2006). “Quality, Fourth Edition.” New
Jersey, Pearson Prentice Hall.
process online. For example, e-procurement provides
[9]. Xu X.X. and Lim R. (2007). “AHP Based Supply Chain
purchasing personnel with an extensive database of vendor, Performance Measurement System”. International Engineering
delivery, and quality data. With this extensive history, vendor Management Conference. pp. 1308-1315.
selection has improved. Electronic files containing engineering
drawing are also available. These resources allow purchasing
agents to attach electronics copies of necessary drawing to
RFQs and inexpensively send the information required to
vendor in matter of hour. Therefore, it can save time and lower
Open Science Index, Industrial and Systems Engineering Vol:3, No:5, 2009 waset.org/Publication/565
the cost.
IV. CONCLUSION
In the nutshell, the authors conclude that business process
re-engineering (BPR) has improved supply chain management
at IHM. By introducing e-procurement, it is indirectly
enhanced the supply chain information system as well as
productivity and reducing supply errors. Problem on delivery
and outsourcing which are the major problem in IHM were
managed properly in short period with better production
system. The authors also found that new business operation is
encouraging the employee to do better job while adopting
Japanese work culture in effort. Besides, by having the top
management involvement in every single activity in IHM is
one of the main reasons for the SCM success.
ACKNOWLEDGMENT
REFERENCES
International Scholarly and Scientific Research & Innovation 3(5) 2009 416 ISNI:0000000091950263