Disciplined cash and working capital management drives good operational and financial performance. However, performance in order to cash, inventory management and procure to pay  slumped over the 5 years prior to the COVID outbreak. A closer analysis reveals that inventory optimisation poses companies the biggest challenge – both in volatile and non-volatile markets. More Cash – Lower Inventory – Better Service, good inventory management is the key.

DELIVER DOUBLE DIGIT INVENTORY REDUCTIONS AND MAINTAIN OR IMPROVE SERVICE LEVELS

Decades of experience have taught us that going straight for the inventories themselves is both the quickest and the surest way of delivering a high-performing supply chain. Inventory sits right at the heart of your supply chain and is both a symptom and cause of your supply chain performance. Getting inventory right keeps your customers happy, increases flow and reduces cost and waste and frees up cash.

At Axisto, we combine the practical business focus of management consulting with the high-speed analytical capability of advanced information technology. We rapidly distil practical insights from data in Enterprise Resource Planning (ERP) systems. Our people concentrate on the human challenges of implementing and sustaining resilient and lean supply chains.

Our unique approach to supply chain puts inventory optimisation front and centre. This allows us to help deliver double digit reductions in inventory while maintaining or improving service levels – at speed in a low risk manner compared to traditional approaches.

OUR INVENTORY MANAGEMENT PROPOSITIONS

Axisto provides three inventory management propositions: inventory optimisation programmes, inventory analytics and inventory maturity assessments.

Our starting point with most clients is a quick scan. On the basis of just 3 standard reports from your ERP system, we quantify improvement potential item by item as well as overall. The output is both an immediate high-level quantification of improvement potential and the basis of a road map to deliver sustainable improvements quickly.

INVENTORY OPTIMISATION PROGRAMMES

We provide expert analytics and effective change management backed up by a clearly measurable business case. Improvements to inventory positions of 20% or more, sometimes much more, are usually achievable within the first year, at a high return on investment.

 INVENTORY ANALYTICS

Do you find it difficult to really understand what your inventory data is telling you, or what you should do about it? Do you have optimisation tools that are difficult to use or which give results you know to be wrong, but you’re not sure why? With the proprietary technology that we use, we provide clients with rapid actionable insights into their inventory data.

In addition, we help clients with a range of targeted analytical exercises, ranging from strategic inventory positioning (where in your supply chain should you hold inventory?) through to setting inventory policies for items that are hard to optimise, such as spare parts, or make to order products.

INVENTORY MATURITY ASSESSMENTS

Inventory is influenced by almost every aspect of your business. Therefore, it can be hard to know at an enterprise level where the biggest opportunities for further improvement are, or how you compare to your competitors.

Axisto can take the temperature of your inventory management. We combine a granular, bottom-up quantitative assessment of your potential for improvement with a qualitative overview of your people, processes and systems, including relevant benchmarks, to give you actionable insights into where to find the next step change in your performance journey.

A CASE

CHALLENGE

A medium-sized industrial manufacturing firm with a strong market position and profitability had little historical focus on inventory. The consequence was that inventory was increasing gradually. It was time to act.

RESULTS

Inventory was reduced by more than 50% from the initial baseline over a period of 3 years, while service levels were maintained or improved. Improvements in the underlying data led to a better understanding of how and why to act – inventory management capability was significantly developed within the client’s teams.

SOME QUOTES

“We finally have full transparency of what we have, so we can make fact-based decisions on a weekly basis.” – Automotive manufacturer

Since starting a programme, we have reduced our inventories by over 50%.” –  Industrial manufacturer

The results are exceptional and have made a major difference to our cash flow.” – Global manufacturing company

The inventory programme brought a wide range of process issues into sharp focus, with an impact much broader than just inventory.” – Market-leading manufacturer

CHALLENGE

A supplier of consumables to the aluminium-smelting industry had been struggling with high-cost pressures and its ability to make product at a commercially viable price. It had taken drastic action by slashing costs across the organisation and cutting deep in the CAPEX budget.

Unfortunately, this left the company unable to respond effectively to a significant increase in demand. Operational problems multiplied, delivery performance fell and clients became nervous.

APPROACH

The key to improving production reliability was restoring the equipment reliability. We started with two parallel actions. One action focussed on reassessing the critical equipment and restoring it to a sufficient ‘base condition’.

The second action focussed on implementing an effective ‘short interval control’. This involved fostering a productive cooperation between production and maintenance, developing more effective behaviours in planning & scheduling and work execution, installing a fitting meeting & reporting structure and ensuring an effective break down notification and elimination process.

From the basis that was created by these two parallel actions, we to develop the level of professionalism that was required: In behaviours, methods & tools, communication, quality of the maintenance master plan and craftsmanship.

Digital transformation programmes, a new strategy, performance improvement programmes are all notoriously difficult to implement successfully. The vast majority change initiatives struggle to achieve and maintain the planned programme goals. In fact, only 30% are successful. Timely and complete delivery of a critical initiative is therefore the true determinant of competitive advantage for any company.

 The vast majority of change initiatives stumble over the very thing they are trying to transform: the attitudes and behaviours of people at all levels of the organisation. Our Change Insider® (CI) measures people’s attitudes and behaviours towards the initiative and how they experience it. Based on these insights, the CI facilitates concrete strategic and tactical actions you need to take to make sure your change initiative is delivered successfully: on time, in full and in a sustainable manner.

HOW THE CHANGE INSIDER® ENSURES SUCCESS

The CI measures people’s perception of an initiative and how they experience it. This is done by asking a number of custom-designed questions as part of a short online survey that takes about 6 minutes to complete. The questions are created by collaborating with people from a cross-section of your organisation and cover the context, objectives, content and approach of your specific initiative. Therefore, the questions are tailored to your organisation and your change initiative. These are the crucial questions that live in your organisation about this specific initiative.

Everyone within the scope of the initiative answers these crucial questions. They do this in a confidential manner and can also add further comments. The survey results are then presented in practical, actionable reports for every relevant cross-section of your organisation.

The reports allow you to compare business units, departments, teams and levels in the organisation. You can see how your people are experiencing the initiative and how the chosen approach influences both the adoption of the change and the actual change itself. The feedback also highlights any differences between different levels or parts of the organisation. Therefore, you can carry out differentiated interventions and keep the entire initiative on track. The survey is repeated at fixed intervals. This way, the CI tracks the effect of interventions on the adoption of change, the actual change itself and the perception of the initiative over time. This provides information about what needs to be done when and where in the organisation to achieve the desired progress and sustainability of the change (see Figure 1).

Axisto Change Insider - perception of the change initiative
Figure 1. An example from an CI report that demonstrates how people are experiencing the initiative by showing the development of answers to critical questions over two survey cycles.

The goal of the Change Insider® is very different to employee engagement surveys. The CI focuses on bringing about sustainable change with a specific initiative. Employee engagement surveys measure how dedicated employees are to their workplace or their employer.

THE DYNAMICS OF CHANGE

People’s ability to change their attitudes and behaviours is determined mainly by their perceptions and intentions. So we must first change perceptions and intentions before any change in attitudes and behaviours occurs. But how do we do this? The best way to influence people’s perceptions and intentions is to provide information and encourage people to gain new experiences.

Perceptions and intentions record people’s motivations and are indicators of how hard people are willing to try or how much effort they intend to put in to display the required behaviour. During a change process, people are confronted with two forces: first, a change tension (the perceived need and urgency of the initiative) and, second, the power to change (the willingness to support and adopt the change and the ability to contribute). Both forces are needed in a programme to bring about change.

The way people experience these forces is the most important indicator of people’s perceptions and intentions towards an initiative. The rating for these two indicators gives the best prediction about a person’s intention to adopt the attitude and behaviour that is required. In different parts and levels of the organisation, the two forces are likely to develop differently, as shown in Figure 2. This drives the need for specific interventions for different parts of the organisation.

Axisto Change Insider - adoption of change - change tension and power to change
Figure 2. An example from an CI report showing the survey results of three teams (A, B, M) and the development of the effects of interventions over two survey cycles. The teams and their development can easily be compared.

The Change Insider® provides fact-based guidance for precisely these differentiated interventions to enable the timely and complete delivery of your mission-critical initiative.

CHALLENGE

The owner had previously managed the company with a high level of entrepreneurship and energy, but with little attention to processes and organisational issues. On the surface the company appeared successful, but it lacked a solid foundation.

Some of the issues: decreasing on-time delivery (OTD), multiple product quality issues, low customer satisfaction and a declining profit margin.

APPROACH

A new top management team was already addressing the factory layout to optimise flow and enhance housekeeping. Axisto was invited in to improve production control and to develop a more professional middle management team.

We worked closely with the middle managers in Production, Work Preparation and S&OP to better align departments and improve their performance.

A more effective ‘short interval control’ was introduced to drive daily and weekly performance to KPI targets. Management and team leaders focussed more on First Time Right quality, and communication between departments was improved. In addition, some team leaders were assigned to other departments to ensure a better fit.

“Tell me where you spend your money and I will tell you what your strategy is.” There is probably no better sentence to describe the potential difference between an intended strategy and a defacto strategy. Zero-based budgeting (ZBB) is a powerful approach to accelerate growth, create value and make your strategy happen.

WHAT IS ZERO-BASED BUDGETING?

ZBB starts from a blank sheet of paper, not from last year’s budget. On a very granular level, you start by determining what resources various business units require to deliver the strategic goals. You then address individual cost categories across all business units and justify all expenditure. In ZBB the base line is not last year’s budget, but “zero”.

ZBB was introduced in the 1960s and was slow in getting traction. It had a brief spell of popularity and then sank away into obscurity. Now, supported by progressed digitisation, it is on the rise again. But it’s no longer just being used in the consumer packaged goods industry, nor focused only on sales and general administrative expenditure. It has begun to spread across industries and functions. And rightfully so because ZBB is appropriate for any industry and all functions: procurement, supply chain, sales and marketing, service and support, and others.

ZERO-BASED BUDGETTING IS NOT JUST A COST-CONTROL TOOL

Many companies use it as a cost-control tool. However, this is vastly underestimating its real power. When used in a strategic context, ZBB can reconfigure cost structures, free up investment funds and accelerate growth. Successful companies start with a solid “What by How” objective that gives the company direction. The related goals then lead to questions about which investments are necessary and what the total cost structure needs to be to enable these investments. This way, ZBB is tightly integrated with the company’s strategy. It addresses both the cost discipline and the investments and opportunities that drive growth. However, using ZBB as a one-time exercise won’t cut it.

ZERO-BASED BUDGETING TRANSFORMS YOUR BUSINESS

ZBB is not a one-time exercise; it is a way of doing business and part of the DNA of an organisation. Its implementation not only redesigns your processes, policies and systems, but also instils new mindsets and behaviours. ZBB establishes clear cost accountability and disciplines to reduce and permanently eliminate costs that add little or no value. At the same time, it establishes a clear accountability to maximise the added value of the right expenditure. ZBB challenges companies to operate more efficiently and effectively across functions, geographies, divisions and business units to grow the top line and margin. It drives people to make conscious, strategic decisions and to get the right things done.

ZERO-BASED BUDGETING IN GOOD TIMES AND IN BAD TIMES – MAINTAIN STRATEGIC MOMENTUM

During a recession – and more so just afterwards – successful companies grow their EBIT whereas others stall. So why do some companies win while others lose? The common denominator with the winners is that they maintain a strict cost discipline and fund their growth levers in both the high and low phases of the economic cycle. They maintain strategic momentum regardless of market conditions.

We know that the total shareholder return a company achieves is mainly determined by its margin. The companies that generate a significantly higher long-term value grow their EBIT most and implement the required change during economic highs – i.e., pre-emptively. So the earlier a company transforms, the better its future performance.

AND WHAT ABOUT LEAN SIX SIGMA (LSS)?

Lean is often talked about as being an extensive toolbox. This misses the point. Lean is all about mindset and behaviours – it’s about strict cost discipline and fast cash conversion cycle. Lean originated at Toyota when it was rebuilding its business just after World War II. The company was cash strapped – as were its customers.

The whole concept of flow within Toyota’s way of working was, and still is, to ensure a fast cash conversion cycle and eliminate low value-added costs. What’s more, they approached everything from the customer’s point of view – what is the customer willing to pay for? Everything else is waste. Having a fast cash conversion cycle creates the opportunity to grow faster. And that is what they did.

Similarly, Six Sigma is often talked about as being an extensive toolbox. But Six Sigma is also all about mindset and behaviours – one of relentlessly eliminating variation. Six Sigma was developed at Motorola in the late 1980s. The company was crippled by the cost of poor quality, which drained their margins and eroded their revenue. For the company to have a viable future, it had to drive down variation.

SO HOW ARE ZERO-BASED BUDGETING AND LEAN SIX SIGMA RELATED?

Zero-based budgeting is the overarching approach to drive the short- and long-term success of a company. From a business strategy point of view, first the “What by How” objective is set and then the top goals and targets are set. ZBB views the company as a whole from the highest level, informed by its purpose, vision and ambition. It affects every aspect of a company: the operating model including the organisation structure and policies. ZBB thrives on the right mindset and behaviours that are incorporated in the DNA of the organisation.

The mindset and behaviours behind Lean Six Sigma (LSS) fit fully with the mindset and behaviours behind zero-based budgeting. ZBB will steer the selection of tools from the LSS toolbox that best contribute to the business needs in the company’s drive to deliver on its vision and ambition – in the same way that Toyota and Motorola developed and acquired skills and tools that were in line with their business needs and informed by their mindset.

Disciplined cash and working capital management drives good operational and financial performance. However, performance in order to cash, inventory management and procure to pay  slumped over the 5 years prior to the COVID outbreak. A closer analysis reveals that inventory optimisation poses companies the biggest challenge – both in volatile and non-volatile markets. More Cash – Lower Inventory – Better Service, good inventory management is the key.

DELIVER DOUBLE DIGIT INVENTORY REDUCTIONS AND MAINTAIN OR IMPROVE SERVICE LEVELS

Decades of experience have taught us that going straight for the inventories themselves is both the quickest and the surest way of delivering a high-performing supply chain. Inventory sits right at the heart of your supply chain and is both a symptom and cause of your supply chain performance. Getting inventory right keeps your customers happy, increases flow and reduces cost and waste and frees up cash.

At Axisto, we combine the practical business focus of management consulting with the high-speed analytical capability of advanced information technology. We rapidly distil practical insights from data in Enterprise Resource Planning (ERP) systems. Our people concentrate on the human challenges of implementing and sustaining resilient and lean supply chains.

Our unique approach to supply chain puts inventory optimisation front and centre. This allows us to help deliver double digit reductions in inventory while maintaining or improving service levels – at speed in a low risk manner compared to traditional approaches.

OUR INVENTORY MANAGEMENT PROPOSITIONS

Axisto provides three inventory management propositions: inventory optimisation programmes, inventory analytics and inventory maturity assessments.

Our starting point with most clients is a quick scan. On the basis of just 3 standard reports from your ERP system, we quantify improvement potential item by item as well as overall. The output is both an immediate high-level quantification of improvement potential and the basis of a road map to deliver sustainable improvements quickly.

INVENTORY OPTIMISATION PROGRAMMES

We provide expert analytics and effective change management backed up by a clearly measurable business case. Improvements to inventory positions of 20% or more, sometimes much more, are usually achievable within the first year, at a high return on investment.

 INVENTORY ANALYTICS

Do you find it difficult to really understand what your inventory data is telling you, or what you should do about it? Do you have optimisation tools that are difficult to use or which give results you know to be wrong, but you’re not sure why? With the proprietary technology that we use, we provide clients with rapid actionable insights into their inventory data.

In addition, we help clients with a range of targeted analytical exercises, ranging from strategic inventory positioning (where in your supply chain should you hold inventory?) through to setting inventory policies for items that are hard to optimise, such as spare parts, or make to order products.

INVENTORY MATURITY ASSESSMENTS

Inventory is influenced by almost every aspect of your business. Therefore, it can be hard to know at an enterprise level where the biggest opportunities for further improvement are, or how you compare to your competitors.

Axisto can take the temperature of your inventory management. We combine a granular, bottom-up quantitative assessment of your potential for improvement with a qualitative overview of your people, processes and systems, including relevant benchmarks, to give you actionable insights into where to find the next step change in your performance journey.

A CASE

CHALLENGE

A medium-sized industrial manufacturing firm with a strong market position and profitability had little historical focus on inventory. The consequence was that inventory was increasing gradually. It was time to act.

RESULTS

Inventory was reduced by more than 50% from the initial baseline over a period of 3 years, while service levels were maintained or improved. Improvements in the underlying data led to a better understanding of how and why to act – inventory management capability was significantly developed within the client’s teams.

SOME QUOTES

“We finally have full transparency of what we have, so we can make fact-based decisions on a weekly basis.” – Automotive manufacturer

Since starting a programme, we have reduced our inventories by over 50%.” –  Industrial manufacturer

The results are exceptional and have made a major difference to our cash flow.” – Global manufacturing company

The inventory programme brought a wide range of process issues into sharp focus, with an impact much broader than just inventory.” – Market-leading manufacturer

CHALLENGE
The success rates of Turn Arounds (TAs) within a global oil and chemical company have continued to deteriorate over the years in terms of safety, time and budget overruns.
The last TA in the Netherlands had been difficult and had delivered, among other things, a number of people suffering from burnout.
Axisto was invited to help to turn the tide and to support the TA team to make this TA an international showcase.

APPROACH
Together with all key people we developed a crisp and clear vision on ‘The Best Ever Turn Around’. It was built on their collective knowledge and experience.
In a coordinated process the vision was shared with next levels of the organisation. It was carefully explained and everyone was invited to contribute. This resulted in a vision that was owned by everyone involved, including the contractors.
The vision was combined with a simple but effective performance board as part of the overall visual management approach. Together with some light-touch coaching on-the-job, this resulted in a great teamwork not seen before in previous TAs.
Both production plants are back in operation and the results are impressive. The final evaluation showed additional improvement opportunities in Preparation and dealing with the schedule during execution. Good input for an even better next TA!

These days, customers expect shorter fulfilment timeframes and have a lower tolerance for late or incomplete deliveries. At the same time, supply chain leaders face growing costs and volatility. how process mining creates value in the supply chain is by creating transparency and visibility across the supply chain and providing proposals for decisions with their trade-offs for real-time optimisation of flows.

FULL TRANSPARENCY

Instead of working with the designed process flow or the process flow that is depicted in the ERP system, process mining monitors the actual process at whatever granularity you want: end-2-end process, procure-2-pay, manufacturing, inventory management, accounts payable, for a specific type of product, supplier, customer, individual order, individual SKU. Process mining monitors compliance, conformance, cooperation between departments or between client, own departments and suppliers, etc.

VISIBILITY ACROSS THE SUPPLY CHAIN

Dashboards are created to suit your requirements. These are flexible and can be easily altered whenever your needs change and/or bottlenecks shift. They create real-time insights into the process flow. At any time, you know, how much revenue is at stake because of inventory issues, what root-causes are and which decisions you can take and what their effects and trade-offs will be.

 

 

 

If supplier reliability is not at the target level at the highest reporting level, you can easily drill down in real-time to a specific supplier and a particular SKU to discover what is causing the problem in real-time. Suppliers could also be held to the best-practice service level of competitive suppliers.

MAKING INFORMED DECISIONS AND TAKING THE RIGHT ACTIONS

The interactive reports highlight gaps between actual and target values and give details of the discrepancies, figure A. By clicking on one of the highlighted issues, you can assign an appropriate action to a specific person, figure B. Or it can even be done automatically when a discrepancy is detected. And direct communication with respect to the action is facilitated in real-time, figure C.

Fig. A, details of the discrepancies.    Fig. B, pop up to write a task. Fig. C, exchanging information.

HOW PROCESS MINING CREATES VALUE IN THE SUPPLY CHAIN – WRAP UP

Process mining is an effective tool to optimise the end-2-end supply chain flows in terms of margin, working capital, inventory level and profile, cash, order cycle times, supplier reliability, customer service levels,  sustainability, risk, predictability, etc. Because process mining monitors the actual process flows in real-time, it creates full transparency and therefore adds significant value to the classic BI-suites. Process mining can be integrated with existing BI-applications and can enhance reporting and decision-making. We consider process mining to be a core element of Industry 4.0.

CHALLENGE
All current shift supervisors were due to retire within the next 10 years.
Their successors needed to be able to manage their teams in a modern way, focussing on inclusiveness, ownership, good discipline, openness and continuous development.
Furthermore, they had to be able to cope with the ever-increasing digitisation of their workplace.

APPROACH

Our client had come to the conclusion that the current lead operators could not progress to become the “new breed” of shift supervisors. Incidentally, most of them didn’t want that either.

However, working with HR, we developed an approach and a process to begin working with the first group of eight trainees.

The approach is based on the 70-20-10 principle: 70% development through practical assignments, 20% on-the-job coaching and 10% classroom training.

Currently, we are half-way the programme and both the trainees themselves and the site leadership is very enthousiast about the impact

We are look forward to the remainder of the programme. The programme is being codified and documented along the way for a future rollout to the next group of operators.

CHALLENGE
The site had created an appealing vision, and its realisation was seen as crucial for the site’s long-term viability.
However, a year and a half later, little had been achieved and the management team had lost control.
Axisto was hired to help put the realisation of the vision back on track and prevent it from derailing again.

APPROACH

The existing vision and strategic drivers had been relevant and appealing. However, the translation of the vision into strategic goals and targets had been missing. Furthermore, the composition of the Site Management Team (SMT) had changed considerably over the past year.
The first step was to allow a careful onboarding of the new site management team (SMT) members and to strengthen relationships within the SMT. Next, the first step of the Hoshin Policy Deployment process was done, setting level 0 strategy and targets. In a series of consecutive sessions next organisation levels were involved until the shop floor was reached. We followed the ‘catch ball’ process carefully.
Now, threequarters of the year onwards the results are what the SMT was looking for.