降低運費的綠帶項目.ppt

Project Title : Freight Charge Reduction 項目名稱 : 降低運費 Green Belt : Maggie Xu 許玉梅 Division : Shanghai Morgan Carbon 上海摩根碳制品有限公司 Location : Shanghai. China. Asia 亞洲. 中國. 上海 Sponsor : Ray Xu 徐穗 Master Black Belt 黑帶大師: Jiang Ting Feng 蔣霆峰 Project Champion 項目盟主: Li Shuxun 李叔恂 Deployment Champion 推進盟主: Li Shuxun 李叔恂 Executive Champion 行政盟主: Simon Hussey 西蒙 哈賽 Team Members : SMC：Ray/Adrian 徐穗 / 張捷 ECS：Crow / Ada 朱江/ 羅靜芬 Forwarder：FedEx-Julie Wu / Emery-Sam Liu / Shining-Grace Shi 聯(lián)邦-吳建敏 / 伊美利-劉偉華 / 三盈-施佩佩,PROJECT INFO,DEFINE,With continuous growth of import & export business, freight charges are increasing as well. Freight charge reduction project is set up to improve our margin thus to maintain our position in the market.,項目背景 Project background:,DEFINE,確立項目范圍 Establish Project Scope,我們從哪開始？ 問題是什么？ 問題的量是什么？ 相關(guān)的財務(wù)問題是什么？,明確問題描述:運費過高 明確問題改進目標(biāo):降低票數(shù)最多的運費 完成項目的期望時間:2004年8月30日 指定項目成員:徐穗/張捷/朱江/羅靜芬/吳建敏/施佩佩 過程負(fù)責(zé)人及組長: 徐穗 管理層的承諾: 全力支持,精確的問題描述（焦點）:同貨運公司之間的合作無協(xié)議 * 過程的缺陷要點:進口/出口運費均偏高 * 明確的目的（目標(biāo)）:同貨運公司簽定協(xié)議 * 合理的范圍: 設(shè)定目標(biāo)價，要求提供門到門的服務(wù) * 很好地確認(rèn)過程主人:許玉梅 * 管理層的承諾（資源）全力支持,過程專家 許玉梅 步入過程，記錄實際的過程：對每一筆運費進行記錄 缺陷數(shù)據(jù) T-test均值數(shù)據(jù)為$8.17,過程圖PMAP已有 過程專家許玉梅,* 過程圖 PMAP已完成 * 過程改進行動，時間，職責(zé) 計劃2004/4月起采取改進措施,* FMEA FMEA已完成 * 列出潛在的關(guān)鍵因子: 同貨運公司之間的協(xié)議 * 過程改進行動，時間，職責(zé) 均已列入FMEA的推薦措施,現(xiàn)有過程是怎樣？ 過程步驟是什么？ 每個過程的輸出是什么？ 每個過程的輸入是什么？ 過程的哪里產(chǎn)生了缺陷？,過程的潛在失效模式是什么？ 怎樣對潛在的失效模式量化？ 哪些過程應(yīng)該重點關(guān)注？,基本過程 Baseline Process,現(xiàn)有過程能力怎樣？ 客戶的期望是什么？ 過程的歷史表現(xiàn)如何？,基本信息 -供應(yīng)商數(shù)據(jù): 任用貨運公司，不考慮到付運費 -過程數(shù)據(jù):運費單價不一致，均值特別高 -客戶數(shù)據(jù):任用報關(guān)行，價格高 客戶的規(guī)格指標(biāo): 對不同的運輸方式，同不同的貨運公司簽定協(xié)議價格 供應(yīng)商的規(guī)格指標(biāo) 訂價高，利潤最大化,* 控制圖所需的數(shù)據(jù)： -時間效果: 6月份完成測量 -普通原因比特殊原因:未發(fā)現(xiàn)特殊原因,項目困難主要來自普通原因 -過程能力: T-test分析顯示過程特差 * 期望的財務(wù)過程改進利益是什么？運費下降,節(jié)約成本.,確定過程失效模式FMEA ID Process Failure Modes,將過程特性化 Characterize Processes,DEFINE,產(chǎn)品樣本：未改進前的運費 工作人員：許玉梅 測量裝置：用KAPPA對運費進行分析,因果戰(zhàn)略和設(shè)計：Y=f(x) 樣品: 運費 時間： 2004/04 因果分析：找出Y和x之間的函數(shù)關(guān)系,運行因果確認(rèn)的結(jié)果：同供應(yīng)商之間達成協(xié)議 時間：2004/05-2004/08 樣品 運費,關(guān)鍵過程變量：運費單價 過程負(fù)責(zé)人：許玉梅 控制策略：文件化,* MSA: KAPPA * 評估測量系統(tǒng)的變差：KAPPA值0.7，可以接受 * 過程改進的方向 經(jīng)過雙方徹底交流，測量值可接受,* 因果結(jié)果和分析：影響運費的關(guān)鍵因素為供應(yīng)商/運費底價/重量(體積)/票數(shù)/談判 * 過程設(shè)置的改進： 按T-test結(jié)果改進 * 理解變量之間的相互作用；改進運費，以上因素缺一不可,* 改進過程的設(shè)置： 按T-test結(jié)果改進,* 控制計劃：運費控制計劃 交流形式和時間：同組員溝通、2004-08,關(guān)鍵的輸出/變量是什么？ 輸入變量之間有哪些相互關(guān)系？,對關(guān)鍵輸出進行衡量嗎？ 我們能否對關(guān)鍵輸出進行測量？ 現(xiàn)有的測量變差是多少？ 客戶的測量系統(tǒng)能力如何？,最好的過程設(shè)置是什么？ 我們能否確認(rèn)這最好的過程？,我們怎樣維持并控制過程的改進？ 怎樣在公司內(nèi)，向客戶及供應(yīng)商 交流過程的執(zhí)行？,實施過程改進 Implement Process Improvements,評估測量系統(tǒng) Measurement Systems Analysis,確定關(guān)鍵變量 ID Critical Variables,控制/維持過程改進 Control/MaintainProcess Improvements,下一輪持續(xù)改進,DEFINE,1.Customers complain that charges at their sides are too expensive 2.Finance complain that freight charges are high during costing 3.Voice also from internal Senior managers when payment approval made,Voice of Customer：,CTQ: Freight charge,DEFINE,DEFINE,SIPOC,DEFINE,Suppliers: Noise factor SMC: Controllable factor(Decision can be made via selection),關(guān)鍵輸入 Cr:關(guān)鍵輸入 C :可控輸入 N :噪音 S :標(biāo)準(zhǔn)作業(yè)指導(dǎo),DEFINE,Process Map IMPORT,發(fā)訂單,訂單確認(rèn),供應(yīng)商生產(chǎn),貨運公司訂價 及貨運,碼頭卸貨,清關(guān),運輸,N: 訂單,N: 其它客戶價/SMC歷史價/價格波動 S: 歷史生產(chǎn)周期 C: 當(dāng)前生產(chǎn)計劃,N: 原材料 C: 生產(chǎn)計劃,N: 燃油價格 C: 運輸成本 N: 貨物 Cr: 我方運輸總量 N: 發(fā)票/箱單/運單 N: 規(guī)模效應(yīng),C: 裝卸成本 N: 運輸費,C: 人工 C: 單證 N: 海關(guān),C: 司機 C: 卡車 C: 運輸成本,品名/數(shù)量 要求交貨期/發(fā)運方式,單價 承諾交貨期,產(chǎn)品實際交貨期,貨到目的港,卸貨費,清關(guān)費,短途運輸費,請購單,入庫,Process Map EXPORT,生產(chǎn),訂艙,送貨,報關(guān),N: 訂單 N: 圖紙 C: 生產(chǎn)計劃,N:訂艙單,N: 貨物 C: 司機 C: 卡車 Cr: 運輸,N: 貨物 C: 發(fā)票/箱單/核銷單/報關(guān)單/報關(guān)委托書 N: 海關(guān),產(chǎn)品,進艙單,貨物進入海關(guān)監(jiān)管倉庫,放行,關(guān)鍵輸入 Cr:關(guān)鍵輸入 C :可控輸入 N :噪音 S :標(biāo)準(zhǔn)作業(yè)指導(dǎo),Quote to be obtained from forwarder when booking,訂單,發(fā)貨,DEFINE,DEFINE,= Freight charge = Y 1+ Y 2 + Y 3,Y 1 : Import from overseas by air Y 2 : Export via courier Y 3 : Export to HK via sea,Y,Y 1 : Current status：SPC(DDU),DDU price per kg is not controllable；Mean=67.59, which far exceeds our target,High unit price caused high freight charge.,DEFINE,No agreement/negotiation with FEDEX, shipping is based on IP,No agreement with forwarder and never assess price & service,DEFINE,Y 2 : Current status：Courier,Y 3 : Current status：Sea shipment to HK,MEASURE PLAN Measuring is made between one people from SMC IMP&EXP and the other from ECS IMP & EXP. By selecting 20 shipments, the two people use Y or N to judge whether freight charge is expensive or not.,測量系統(tǒng)分析計劃 Measure System Analysis plan,MEASURE,WHY MEASURE ？ To make sure that team members fully understand freight charge is expensive or inexpensive, measure analysis is made to identify thus to control freight charge.,MSA BEFORE IMPROVEMENT,MEASURE,The above chart shows that there are inconsistency between the two people.,MEASURE,KAPPA ANALYSIS Failure of inconsistency is due to the lack of knowledge for price criteria. In test for the second time, weight, one of the most fundamental factors that exert big influence on price is considered, KAPPA performance is within specification.,MSA AFTER IMPROVEMENT,MEASURE,With well communication on unit price , performance for the second chart is much improved.,ANALYSIS,Y = f ( x1, x2, x3, x4, x5 ),x1 : forwarder x2 : Freight charge benchmark x3 : Weight x4 : Nbr of Shpts x5 : negotiation,FMEA - IMPORT,ANALYSIS,FMEA IMPORT ANALYSIS RPN data for pickup plus airport to airport and customs clearance in Shanghai are extremely high, which represent where the central control points are. Charges for air shipment from supplier to SMC include EXW pickup, freight charge, customs clearance in Shanghai and door delivery. To keep all these charges under control, a DDU price needs to be negotiated with forwarder.,ANALYSIS,FMEA EXP VIA COURIER & SEA,ANALYSIS,FMEA VIA COURIER & SEA ANALYSIS RPN data for both export via courier and sea are high. We seem to have become accustomed to the existing things and behavior and people we work with. We have not really accepted the idea of change before we are forced to change.,ANALYSIS,ACTION PLAN,IMPROVE,Make agreement with forwarders. Guideline team members to fully understand current price and help follow up. Request suppliers to use our forwarder instead of their forwarder when making shipment. Monitor freight charges for each shipment before making payment. Target freight charge is $2.2 per kilogram for global import business 40 per cent discount with FEDEX for both import & export business,IMPROVE,Mean CNY 67.6 is the price that comes from the selection of 50 shpts Test of mu CNY 18.26 per kilogram comes from our agreement with Shining P value = 0.006 0.05,One-Sample T: DDU Price Per Kg Test of mu = 18.26 vs mu not = 18.26 Variable N Mean StDev SE Mean DDU Price Pe 51 67.6 122.2 17.1 Variable 95.0% CI T P DDU Price Pe ( 33.2, 102.0) 2.88 0.006,Y 1 : Improvement for Import via air,Significant Improvement,Agreement Hereunder rate we Shining Freight Forwarding confirm as listed below. Tradelane : Overseas Shanghai Service Type : Standard, via air Service Requirement : Door to Door DDU charge : $2.2 per kilogram $2.2 per kilogram includes airfreight(airport to airport), fuel & security surcharge, door pickup, terminal charge in the overseas, terminal charge in Shanghai, customs clearance, door delivery, storage charge. In case of customs inspection, charges will be subjected to Shanghai Morgan. Shining Forwarding Co., Ltd. 28, July 2004,IMPROVE,IMPROVE,Agreement Hereunder rate we Emery Worldwide confirm as listed below. Tradelane : USA SHA Service Type : Standard Service Requirement : Door to Door Airfreight & Origin Charge in States : Airfreight (airport to airport) ：USD 1.3/kg （Flat Rate） Fuel & Security Surcharge ：USD 0.3/kg Door Pickup ：USD 0.2/kg Sub-total ：USD 1.80/kg Plus Terminal Charge ：USD 30 per shipment Total ：USD 1.8/kg + USD 30 per shipment,Shanghai Destination Charge ： Terminal Charge ：RMB 0.9/kg or Min 20 Customs Clearance ：RMB 200 per shipment Door Delivery ：RMB 200 per shipment Storage Charge if Applicable ：RMB 0.1/kg/day (3 days free) Remarks ： Above rates are effective from today Above word of “USA” means all inland points in states Above rates are applied to each shipment that dimensional weight has to be over 45 kgs . Above rates are subject to market adjustment Emery Worldwide Shanghai Branch 30, June 2004,IMPROVE,At year beginning, export agreement with UPS agent 40 per cent for documents and 25 per cent for cargo and no discount for import as UPS does not allow collect. Early June, further import & export agreements with FEDEX 40 per cent for both documents and cargo. Up to 21 kilograms or above, 50 per cent or even more followed by application with FEDEX sales.,Y 2 : Improvement for import & export via courier,Agreement for Import & Export via Fedex,IMPROVE,IMPROVE,With HK customers complaint for high terminal charge, at year beginning, forwarder was changed to meet customers terminal charge requirement. Meantime, handling charge per shipment in Shanghai is reduced to CNY100 from the original CNY550. In March, forwarder requested for a price increase. We soon select a new forwarder CNY50 per shipment to replace the previous.,Y 3 : Improvement for export via sea to HK,CONTROL,SAVING,Actual saving, Mar throu July, 2004,Calculations are based on the followings:,SAVING,Mar04,Saving(CNY),Descriptions,9,807.70,Saving is from UPS and HK sea shipment,Apr04,14,430.30,Saving is from UPS and HK sea shipment,May04,6,748.00,Saving is from UPS/FEDEX and HK sea shipment,June04,16,154.58,Saving is from UPS and HK sea shipment,July04,152,549.60,Saving is from FEDEX/Import via air/HK sea shipment,Actual Saving, Mar.2004 throu July 2004 - CNY199,690.16 Expend