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Managing Supply Chain and Operations An Integrative Approach 1St Edition Foster Solutions Manual Full Chapter PDF
Managing Supply Chain and Operations An Integrative Approach 1St Edition Foster Solutions Manual Full Chapter PDF
Because sourcing is not familiar to all students, this exercise is designed to have them
interview a sourcing professional. This should allow students to have some sense of the
purchasing profession prior to coming to class. Questions are included in the exercise to
structure their interview.
Integrative Experiential Exercise
This exercise is more in-depth in that a team will study a purchasing function within a
company in some depth. Be sure that the teams focus on changes in the purchasing
function and how it has evolved.
Discussion Questions
3. How does strategic sourcing that embraces the lean philosophy differ from the
traditional approach to sourcing decisions?
Under the lean philosophy, strategic sourcing is required to work with other
departments to ensure that the organization has just enough quality inventory at
just the right time in order to reduce the total cost incurred to the entire
organization. This is different from simply purchasing the lowest cost component
that meets the minimum quality requirements.
4. How must strategic sourcing in a lean supply chain analyze its existing
supplier relationships?
Strategic sourcing must analyze its existing supplier relationships on the basis of
total cost of ownership. This will allow a lean organization to ensure that no matter
the source of purchased components, they result in the lowest total cost to the
organization.
5. The role of purchasing organizations has changed over the years. What has
been the focus of the purchasing organization since 2000?
The focus has been on providing a competitive advantage by driving cost savings for
the firm and providing an uninterrupted supply of materials, as well as developing
collaborative relationships to achieve an integrated supply chain.
7. Briefly describe how it is possible for a small change in the cost of purchased
goods and services to have a more significant effect on profits than a large
change in sales.
Savings in the purchasing of materials accrues directly to the bottom line (net
profits), whereas changes in sales volumes are highly leveraged by cost of goods
sold and other operating expenses.
8. Briefly identify the types of purchased goods and services that fall into the
direct spend category, the indirect spend category, and the capital spend
category.
The direct spend category includes any material or service that is part of the final
product. The indirect spend category includes all the spending that supports the
operations of a firm, encompassing everything from cafeteria services to spare parts
for factory equipment. Capital spend, as the name implies, includes all spending for
buildings and large equipment, anything that will be depreciated.
9. Briefly define routine items and bottleneck items and contrast the
appropriate purchasing strategy for the two.
A routine item is typically something of low value, purchased in small volumes,
through individual transactions. Many alternative products and services and many
sources of supply are available for this type of spending. The appropriate strategy
for routine items is to simplify the acquisition process. Supply managers can reduce
the amount of time and effort expended on procuring these items by automating the
purchasing process.
A bottleneck item is one in which there are few alternate sources of supply, typically
due to complex specifications requiring complex manufacturing or service
processes, new technology, or untested processes. Although these items may not
have the profit impact of leverage or critical items, the lack of the item has an impact
on operations. The strategy for bottleneck items is to ensure supply continuity while
also working to move the item to another quadrant in the portfolio matrix.
10. What are leverage items, and how should they be managed?
A leverage item has the potential to impact profit, typically because they are
associated with a high level of expenditures while also having many qualified
sources of supply. When supply managers must to balance large spending quantities
with a broad choice of suppliers, she should work to maximize the commercial
advantage for the firm by concentrating business with a limited number of suppliers
in order to achieve volume discounts and by promoting competitive bidding
between qualified suppliers.
12. What is spend analysis, and what questions can it help answer?
Spend analysis is a review of a firm’s entire set of purchases and answers the
question: On what is the firm spending its money?
13. Identify the purpose and the primary challenge in conducting total cost of
ownership analysis.
Total cost of ownership (TCO) analysis is the process of evaluating the cost of an
item over its entire life, including purchase, maintenance, and final disposition. This
analysis is most useful when there are many suppliers available in the marketplace,
meaning that different items may have different lifetime cost. The primary challenge
in conducting TCO analysis is to be sure you are comparing items with the same
specifications, quality levels, lead-times, warranties, disposition costs, etc. when
comparing TCO. If the items are not identical, the supply manager must account for
that in the TCO analysis.
15. What is should cost modeling, and how does it relate to the supply manager’s
strategic role?
Should cost modeling is the process of determining what a product should cost
based upon its component raw material costs, manufacturing costs, production
overheads, and reasonable profit margins. From a strategic perspective, knowing
approximately what a product should cost enables a supply manager to better
negotiate for a fair price.
Problems
Economics of Purchasing
1. First we need to calculate the net income of the company before potential material
cost reductions and sales improvements. We can calculate this using Figure 6.1.
Cost of Goods Sold = $1,250,000 + $5,000,000 + $710,000 = $6, 960,000
Knowing this information, we can calculate the impacts of the potential changes as
seen in Solved Problem 6.1.
2. We first need to calculate net income of the company before any potential changes.
Use Figure 6.1 to do so.
COGS = 7,500,000 + 1,500,000 + 500,000 = 9,500,000
3. The two suppliers in question offer different prices and different payment windows
for the same part. We need to put the two options into the same terms by
performing a price analysis as shown in Solved Problem 6.2.
• Number of days earlier Supplier A must be paid than Supplier B (longest days to
pay – shortest days to pay)
o 90 days – 30 days = 60 days
• Daily cost of capital
o Cost of Capital/days in a year = .20/365 = .000548
• Opportunity cost = # of days * daily cost of capital * purchase price of A
o 60 * 0.000548 * $100 = $3.288
• Effective price for Supplier A (in like terms as B)
o $100.00 + $3.288 = 103.288
This means that when the two suppliers are compared on equivalent term, Supplier
A’s part is $2.212 less expensive ($105.5 – $103.288) than Supplier B’s part in spite
of the shorter payment window.
4. Using Solved Problem 6.2 we can perform a price analysis to determine from which
supplier we should purchase.
• Number of days earlier Supplier A must be paid than Supplier B (longest days to
pay – shortest days to pay)
o 60 days – 30 days = 30 days
• Daily cost of capital
o Cost of Capital/days in a year = 0.06/365 = 0.000164
• Opportunity cost = # of days * daily cost of capital * purchase price of A
o 30 * 0.000164 * 55.00 = $0.271
• Effective price for Supplier A (in like terms as B)
o $55.00 + $0.271 = $55.271
This means that in spite of the shorter payment window, Supplier A is still the better
choice by 7.9 cents.
5. When performing a price analysis between three companies, two separate price
analyses will be required (A-C, B-C)
A-C
6. Every total cost of ownership analysis can be different as there are different
variables for each scenario. The formula for this copier scenario can be seen below:
Total Cost of Ownership for a Copier = Installation & Setup + Cost per copy * Annual
copies * Useful life
Although the initial setup and installation costs for Copier II are higher, the total
cost of ownership is less expensive for Copier II.
7. Every total cost of ownership analysis can be different as there are different
variables for each scenario. The formula for this food processing motor scenario can
be seen below:
Total Cost of Ownership Annually for a Motor = (Annual operating hours/Useful life
* Price per motor) + (Annual operating hours * Energy Cost per hour)
Although the purchasing price of Supplier A’s motors is higher, the useful life is
longer requiring fewer replacements per year in addition to lower energy
consumption. The net result is that it will be less expensive to use Supplier A than
Supplier B for our food processing motors annually.
8. Every total cost of ownership analysis can be different as there are different
variables for each scenario. Assuming the company uses the machine for its entire
useful life, the formula for this custom part production machine can be seen below:
Total Cost of Ownership Annually for a Machine = [Machine Price + (Annual
production * Machine life/Component life * Component cost)]/Machine Life
This means that assuming each machine is used its entire useful life, the annual total
cost of ownership for Machine B is $1,200 less expensive than Machine A. It should
be noted that if the company believes they will only use the machine for two or
three years, a slightly different calculation would need to be performed.
9. Using Solved Problem 6.4, we can calculate the total cost of outsourcing motor
manufacturing.
According to the above analysis, producing the motors in Mexico would result in a
$1.00 savings per motor. However, because of the closeness in cost, other factors
and risks should be taken into consideration before making a decision.
Question
Cathy needed a report by next Tuesday that outlined in general terms how procurement
could assist in improving the company’s competitive position. Describe what
procurement’s role might be in new product development, and provide a detailed analysis
of the effect of a 30 percent increase in sales versus an 8 percent reduction in material
costs.
Answer
Purchased goods and services make up 50 percent to 90 percent of a firm’s cost of goods
sold. With the responsibility for such a large percentage of cost of goods sold, a
procurement organization and its supply managers have a tremendous opportunity to
affect the profitability of a firm. That effect can be seen in the cost of purchased products
and services, the quality of purchased goods and services, and the cost built into the
product or service during development and design.
The first, and most obvious, impact a sourcing manager has on profitability is
through the cost of purchased products and services. In fact, a small change in the cost of
purchased products and services can have a more significant impact on profits than a large
change in sales.
A procurement organization with strategic sourcing in mind is also focused on the
quality of goods and services. Sourcing materials and services with higher levels of quality
can affect profitability. The manufacturer may also see an impact on profitability from
improved quality conformance when defect rates drop and there is less waste due to faulty
parts.
Sourcing materials
or services with
improved quality
Higher profitability
supplier involvement in the design process, which has been found to help reduce cost,
reduce concept-to-customer development time, improve quality, and provide innovative
technologies that can help capture market share.
Decreasing materials costs by 8 percent will result in an increase of profits of $480,000 and
will increase the profit margin from 6 percent to 11.33 percent (See the figure below).
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