Professional Documents
Culture Documents
Supply Chain Literature 3-2
Supply Chain Literature 3-2
Regine Slagmulder
SummalY:
Supplier and customer-focused cost information enables firms to identify
opportunities for improving the cost efficiency of their transactions with supply
chain partners. It is the first step towards interorganizational cost management,
which is a structured approach to coordinating the activities offirms in a supply
chain so that overall costs are reduced. Coordinating the cost-reduction programs
of firms across the supply chain can help them identify ways to make their
interfaces more efficient. In addition, it can help the firms and their buyers and
suppliers find new ways to jointly reduce the manufacturing costs of their
products, both during product design and manufacturing.
Keywords:
Interorganizational Cost Management, Supply Chain, Activity-Based Costing, Target
Costing, Buyer-Supplier Relationship
from activity-based costing approaches for managing the costs of transactions with
suppliers and customers. Section three extends the subject beyond the firm's
boundaries and discusses various approaches for interorganizational cost
management during product design and manufacture. Section four highlights the
characteristics of buyer-supplier relations that enable the effective use of these
cost management techniques. The final section concludes the paper with a
summary.
The first step in interorganizational cost management consists of the firm getting
together with its buyers and suppliers to find ways to make their interfaces more
efficient. An important element in making the interface more efficient is reducing
uncertainty, for example by increasing information sharing and shortening cycle
times. Reducing uncertainty in such a way may lead to significant savings as both
the buyer and the supplier can keep lower levels of buffer inventory.
Suppliers can help increase the efficiency of the buyer-supplier interface by
changing their behavior to reduce procurement costs at the firm. For example, if
the firm is operating in just-in-time mode, late deliveries by suppliers are very
expensive. Based upon its analysis of procurement costs, the firm can show the
supplier the high costs associated with poor delivery performance. The supplier
can then initiate a program to increase on-time deliveries. The firm can help in this
process by transferring the expertise it has gained in its own journey towards lean
thinking. Other potential improvements for the supplier include improved quality,
smaller batch deliveries, and shorter lead times.
Alternatively, buyers can change their behavior in ways that reduce the firm's
customer service costs. For example, the buyer may be placing a large number of
small orders with the firm. If the firm has high sales order processing costs, then
the firm's cost to serve that customer will be high. The firm can use the insights it
gains into the economics of customer service to suggest new ways for the buyer to
order products. For example, the buyer might agree to undertake data entry that
feeds directly into the firm's sales order systems. Other potential improvements
for the buyer include reducing its reliance on custom as opposed to standard
products, ordering as many different products at a time as possible, increasing
sales order lead-times, and reducing the number of changes to sales orders.
The interfaces between the firm and its buyers and suppliers will only become
tmly efficient when they in tum ask the firm to modify its behavior to reduce their
costs. Many of the recommendations will lead to cost savings at both sides. For
example, adopting Total Quality Management not only reduces costs at the buyer
by removing the need to inspect incoming items or return defects, but also at the
supplier by eliminating rework or scrap. Similarly, both sides can achieve savings
by adopting electronic data interchange (EDI). The critical point is that there are
win-win scenarios that can be identified by extending cost management beyond
the walls of the factory and realized by extending it beyond the boundaries of the
firm.
In addition to optimizing the buyer-supplier interfaces, the supply chain can also
be made more efficient by having the firm and its buyers and suppliers jointly look
for ways to reduce manufacturing costs. Some cost management techniques are
applied to reduce costs during the product design stage, whereas others are used to
reduce costs during the manufacturing stage.
Managing Costs Across the Supply Chain 81
discipline of target costing can be extended from a single firm to multiple firms in
a supply chain.
2. Functionality-Price-Quality Trade-Offs
One of the outcomes of target costing is that the firm establishes its suppliers'
selling prices. Since these prices reflect the cost pressures that the firm faces in the
marketplace, it communicates these pressures to the firm's suppliers. When a
supplier finds that it cannot achieve the target costs set by the buyer's component-
level target costing process, it can initiate additional interorganizational cost
management activities (see Figure 2).
FPQ
Trade-Offs
Target Interorganizational
Costing Cost Investigations
Concurrent
Cost Management
The degree to which the design teams of the two firms interact under the various
techniques varies significantly. At one end of the spectrum are functionality-price-
quality (FPQ) trade-offs, which involve only minor reductions in the outsourced
component's quality, functionality, and cost, and which have no impact on the
specifications of the end product. Under an FPQ trade-off, the buyer and supplier
negotiate to lower the level of quality and functionality required so the supplier
can generate an adequate profit at the buyer's component-level target cost. For
example, costs might be reduced if a casting is used instead of a more expensive
forging. The firm's engineers know by how much surface tolerances can be
relaxed before the quality and functionality of its product suffer, and the supplier's
engineers know the tolerances that can be achieved using castings and forgings.
Thus, only when the two design teams interact and coordinate their activities can
an acceptable, low-cost castings solution be identified.
The feasibility of an FPQ trade-off depends upon the willingness of the buyer to
relax the quality and functionality specifications established for the component. If
the supplier can negotiate such relaxations, it will be easier to achieve the
component's target cost. For example, if the component is allowed to have lower
functionality, its design might be simplified so that the number of parts it contains
can be reduced. Such a parts reduction can lead to lower cost. The willingness of
the buyer to allow such relaxations is constrained by the need to maintain the
Managing Costs Across the Supply Chain 83
specifications of the end product itself. The supplier must understand the role of
the component in achieving the end product's functionality so that it can make
appropriate recommendations.
3. Interorganizational Cost Investigations
The interaction between the design teams can be extended to several firms in the
supply chain. For example, imagine a situation in which one firm produces a
forging or casting, another one machines its surface, and a third one uses the final
component in its end product. In this scenario, the knowledge required to find new
low-cost solutions resides at three firms. Therefore, to find creative ways to reduce
costs requires that design teams from the three firms get together. These
interactions are called interorganizational cost investigations. The important point
is that a new lower cost solution can only be identified through the coordinated
effort of the three design teams. In an interorganizational cost investigation, the
design teams of the firms get together to determine whether the specifications set
by the buyer can be altered in ways that enable the component's costs to be
reduced significantly. The changes to the component's specifications usually are
greater than those considered under an FPQ trade-off.
The objective of interorganizational cost investigations is to find ways to redesign
the products and the components they contain so that they can be manufactured at
their target costs. Consequently, the first consideration is what changes can be
made to the design of the end product and the components it contains. Since the
design changes made to the components may affect the specifications of the end
product, the supplier cannot initiate them unilaterally. Instead, the buyer and
supplier design teams must get together to identify which design changes are
acceptable to the buyer and reduce costs across the supply chain.
The second consideration deals with changes in the production process that
require moving production activities across organizational boundaries. If certain
activities can be performed more efficiently at another firm in the supply chain,
then costs will be reduced if these activities are moved. Second, if collocating two
activities allows costs to be reduced, then shifting one of the activities so it is
performed in the same location as the other will allow costs to be reduced. Finally,
if changing the production process can eliminate certain activities, then costs will
also be reduced. For example, if there is a way to start with raw material that has a
smooth surface as opposed to a rough one, then the production step preparing the
surface of the rough component can be eliminated.
As the product design and production processes are modified, the costs incurred in
each firm change. These changes often require the target costs of the components
to be modified. For example, if costs are increased at one firm and decreased at
another (but reduced overall), then the target cost of the component at the firm
with increased costs may need be raised and at the firm with the lower costs,
reduced. These changes redistribute the cost-reduction objectives and hence profit
84 R. Slagmulder
levels among the firms in the supply chain. Typically, the firm that is most
upstream in the supply chain sets the new target costs.
4. Concurrent Cost Management
Under concurrent cost management, the most interactive of the interorganizational
cost management techniques, the design of the entire major function is outsourced
to the supplier. Consequently, this interorganizational cost management technique
involves intensive interactions during the product design phase, where both sides
make suggestions for cost reduction leading to significant changes in the design of
the product and the components that it contains.
For concurrent cost management to be practiced, the suppliers need to develop the
necessary expertise so that the buyer can relinquish design responsibility to them.
If the two design teams can operate essentially in isolation, then parallel
engineering is appropriate. The buyer's team provides the supplier's team with
high-level specifications such as size, capacity, and effectiveness. The two teams
are then free to operate independently as long as they do not make any design
changes violating the high-level specifications of the product or the component.
While the two design teams operate in isolation, they maintain contact with each
other to ensure that they achieve their joint objectives.
However, if the buyer and supplier design teams cannot effectively operate in
isolation, simultaneous engineering is used to design the product and component
concurrently. In simultaneous engineering, the two design teams work closely
together to identify ways to increase the quality and functionality of the end
product and its major function, while at the same time reducing overall costs. The
two design teams make suggestions to alter the design of both the end product and
the major function, which could not be made if the two teams acted in isolation.
For example, redesigning the component to reduce its costs may require some
major changes in the design of the end product. Identifying the scope of such
changes and whether they reduce overall costs without sacrificing quality and
functionality requires frequent interactions between the design teams.
Additional opportunities for joint cost reduction in the supply chain occur during
the manufacturing phase. Interorganizational cost management during product
manufacture is a structured approach to coordinating the production activities of
firms in the supply chain so that the products and components those firms produce
can be manufactured at their kaizen costs. The starting point for setting a kaizen
cost-reduction objective is the price pressure that the firm is exposed to in the
marketplace. This kaizen cost-reduction objective then has to be decomposed to
the supplier level. In kaizen programs, suppliers usually are subjected to a flat
Managing Costs Across the Supply Chain 85
cost-reduction rate, for example, 3% per year. This approach differs significantly
from the one used for target costing, where specific targets are set at the individual
product level. In kaizen costing, specific cost-reduction objectives are set only for
very expensive components (for example, 6% for radiators and 3% for starter
motors).
If some suppliers are unable to achieve the cost-reduction objective, additional
cost-reduction efforts are required. The buyer and supplier can cooperate in three
ways to further reduce costs. First, the buyer can use its engineering expertise to
help the supplier find lower-cost ways to manufacture the components it sells to
the buyer. Second, if such solutions cannot be identified, the buyer can change the
design, but not functionality, of its product to enable the supplier to develop new,
lower-cost components. For example, several integrated circuits might be
combined into a single chip. This solution lowers the cost for the supplier, but
requires that the buyer change its circuit design. Finally, the buyer can agree to
change its production processes, but not product designs, to accommodate changes
in the supplied component. For example, the buyer might agree to perform
machining operation in house because it can be integrated with an existing one at a
lower cost than the supplier can undertake. In that case, the supplier's kaizen cost
might be adjusted downwards to allow for the additional cost borne by the buyer,
but overall the supplier will be better off because the downward reduction is less
than the avoided costs. Alternatively, the buyer can agree to shift some operations
to the supplier and accordingly adjust the kaizen cost upward. Again, the supplier
will be better off if the increase in the kaizen cost is greater than the costs incurred
to perform the new operations. The firm can also help its suppliers reduce costs in
other ways. For example, the firm can use the combined buying power of the
supply chain to negotiate better discounts than its suppliers can achieve on their
own.
5 Summary
Interorganizational cost management is an approach to cost and profit
management that takes advantages of synergies existing across multiple firms in a
supply chain. Unlike traditional costing systems that have failed to provide an
accurate analysis of costs beyond the production domain, activity-based costing
systems help firms to more accurately assign the costs associated with supplier
and customer relationships. This supplier and customer-oriented cost information
enables firms to identify opportunities for increasing the cost efficiency of their
trading relationships within the supply chain.
Cost synergies can also be realized by actively coordinating activities among firms
in the supply chain, with the aim of reducing overall supply chain costs.
Managing Costs Across the Supply Chain 87
6 References
Cooper, R., Siagmuider R. (1997): Target Costing and Value Engineering, Productivity
Press, Portland, OR.
Cooper R., Siagmuider R. (1998): Strategic Cost Management - What is StrategIc Cost
Management?, in: Management Accounting, Vol. 76, No. I (1998), p. 14-16.
Cooper, R., Slagmuider R. (1999): Supply Chain Development for the Lean Enterprise.
Interorganizational Cost Management, Productivity Press, Portland, OR.
Cooper, R., Yoshikawa T. (1994): Inter-Organizational Cost Management Systems: The
Case of the Tokyo-Yokohama-Kamakura Supplier Chain, in: International Journal of
Production Economics, Vol. 37 (1994), p. 51-62.
Dyer, 1. H. (1996): Specialized Supplier Networks as a Source of Competitive Advantage:
Evidence from the Auto Industry, in: Strategic Management Journal, Vol. 17 (1996),
p.271-291.
Dyer, 1. H., Ouchi W. G. (1993): Japanese-Style Partnerships: Giving Companies a
Competitive Edge, in: Sloan Management Review, Vol. 34, Fall (1993), p. 51-63.
Hines, P. (1994): Creating World Class Suppliers, Pitman Publishing, London.
Kamath, R. R., Liker 1. K. (1994): A Second Look at Japanese Product Development, in:
Harvard Business Review, Vo1.16, Nov.-Dec. (1994), p. 154-170.
Kaplan, R. S., Cooper, R. (1997): Cost and Effect, Harvard Business School Press, Boston.
Lamming, R. (1993): Beyond Partnership. Strategies for Innovation and Lean Supply,
Prentice Hall, New York.
Womack, 1.P., Jones, D. T. (1996): Lean Thinking, Simon & Schuster, New York.