Professional Documents
Culture Documents
Inventory Management
a. Continuous Review Policy 1 (HDTV sets)
Assume a distributor using a Continuous Review Policy: inventory level is
continuously reviewed, and if an order is placed, the order arrives after the
appropriate lead time.
Questions
Calculate the reorder level R, the (optimal) order quantity Q, the expected
average inventory level AVINV, the expected order frequency or time between
orders ETBO and the expected annual inventory turns EAIT.
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The daily inventory holding cost for a unit is 0.2 % of the unit cost.
The replenishment lead time for an order placed by the retailer is 6.25
days.
The expected service level is 95%: assume that the corresponding z-value
is 1.65 (rounded to two decimals).
Questions
3. Assume that replenishment lead time can be reduced (e.g. from 6.25 to
4 days). What is the impact on the five indicators (R, Q, TBO, AVINV,
AIT)? Please explain.
c. (Q, R) strategy
Assume that you are a retailer, ordering a product from your supplier,
using a (Q, R) strategy. The product is bound to a certain lifetime:
demand from your customers is variable and is likely to reduce strongly
in the near future, but it is uncertain when.
Assume a situation of continuous replenishment, a situation in which,
always, a couple of orders are underway from your supplier to your
inventory at retail, hence: the order lead time is typically longer than the
time between subsequent orders.
Questions
3. What will be the impact of an unexpected increase in the order lead time
on the inventory level in the short, in the medium and in the long run?
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4. Draw diagrams of the situations as described above, showing
(characterizing) how the inventory level is expected to develop over
time.
d. Retail strategies
Imagine a large vertically integrated firm, with a production and assembly unit,
a central warehouse, 20 regional distribution centres, and 500 different retail
locations.
The firm has established the appropriate retail service levels for its different
SKUs that will maximize overall net profit (using a 97% overall service level as
a baseline). It has established those levels based on the factors: Per unit
profit margin (“cross margin”), Annual sales (volume in units) and Forecast
error. This has resulted in SKU plots typically looking like the one depicted
below (retail locations are similar).
Questions
1. Assume now that everything else is equal for each SKU (lead time,
stage in product life cycle, expiry date, likelihood of having a substitute
or finding it at a competitor, or at a different price, customer
(dis)satisfaction due to (un)availability, etc, etc).
How can the firm use the typical SKU plot to decide on the inventory
level of an SKU at the different stages (“before assembly”, “central
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warehouse”, “regional distribution centre” and “retail location”) in the
supply chain?
Explain.
2. Assume that the firm is considering a new channel: online sales and
direct shipment. From a supply chain perspective, what type of SKUs
would provide, relatively, the largest advantages versus disadvantages,
when sold online and shipped direct, as compared to sales through a
traditional retail? Explain.
Hint: for this last question consider existing SKUs as well as new
SKUs, and elaborate on how different Supply Chain related factors play
a role.
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Case 2. Beergame and Order Model
(adapted from iseesystems.com)
The following structure, often called the “Over-reaction and amplification
structure” has appeared in a wide diversity of organizations. In case you know
the beergame: it is this very structure that is in the center of the dynamic that
arises in that game. The exposure to the dynamic came up in the context of a
manufacturer of bicycles. The manufacturer experienced swings in inventories
and this led to high costs. At the time iseesystems got involved, the prevailing
explanation for this was that the swings resulted from the fact that demand for
that particular type of bicycle had a strong seasonal component: usually more
bicycles are sold in the summer season than in the winter season. It was
discovered that the manufacturer first created the seasonality and then passed it
on to its suppliers who amplified it. The basic structure is quite simple:
target inventory
inventory correction
The dynamic is probably best understood by imagining that you are taking a
shower on the top floor of a high building. This particular building gets its hot
water from a central source located in the basement. This means that when you
turn on the shower, it takes a while before the hot water reaches you. It also
means that any corrections to the knob settings, the temperature, will take a
while before they are fully felt. Suppose that on a cold morning you go into the
shower as soon as, to the touch, it feels hot enough. After starting to use the
soap and shampoo, you feel the temperature increasing. No problem, you just
crank down the knob. But: you do not feel any effect (thanks to the long pipe), On
the contrary it is even getting hotter. So you crank it again. Still no effect. One
more time: and suddenly the water is freezing. Feeling very cold, you give the
knob a crank upward. No effect. One more, no effect again. One more and
…..scalding!!! And with your body full of soap and shampoo you jump out of the
shower. Essentially the same dynamic was being played out at the bicycle
manufacturer. This, perhaps with different names on the boxes and pipes, can be
found in the context of many organizations. This is a basic planning problem
related to resources being represented. The explanation for the dynamic is that in
placing orders, or adjusting shower controls, only the current state of things was
taken into account. In the shower you over-crack because you are not taking into
account the accumulation of all your cranking. As a result you end up ordering
much more hot water than you really need. Similarly, the bicycle manufacturer
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did not take into account what already had been ordered, what was in the
pipeline. Doing something radical to fix the situation in this kind of case leads to
disasters. This was precisely the case with the bicycle manufacturer ordering
parts. It gets worse when you put together two or more players who are ordering
regardless of “pipelines” and future demands.
Questions
2. Play the order model from the Ithink software. Give an explanation for the
effect you see. What improvements can be made? Define a better
ordering strategy. Go to the double orderer and answer the same
questions
Most strategic planning tools deal with static elements. They can assist us
performing what-if analysis and create different business scenarios. They do not
track, however, the flows of resources over time (such as the movements in
inventories, human resources, market share and cash). The analysis of stocks,
people, money and other assets over time and the problems imposed by the
management of those resources is a challenge that all executives face.
Executives should be brought in a position to use tools that can help them focus
on processes not just on numbers, tools that help them find real causes of
problems, that help them analyze the driving forces of a business/organization
and its environment. Therefore an easy language is required, a language
showing operational relationships, not only statistical ones, a language that can
show how the structure by which our business/organization is actually functioning
or going to function, will work out dynamically. The session will introduce a visual
language appealing to executives and improving the ability to understand, plan,
control and guide a business/organization. This is a way of thinking. Systems
Thinking is the art and science of making reliable inferences about behavior by
developing an increasingly deep understanding of underlying structure. This is
essential when analyzing and designing supply networks.
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Tools for Systems Thinking
One tool that analyses such systems dynamics is Ithink from HPS (Hanover,
NH). The program is based on a formal method that was developed in the late
1950s by Jay W. Forrester of the Sloan School of Management at MIT
(Cambridge, MA). An Ithink model consists of a set of interrelated graphical
variables, which can be connected using a diagram editor. The Ithink simulation
language is used to develop the exact definition of the relationship to be
analyzed. The development of a business model is usually a three-stage
process, First of all, it is important that a team of executives share their views of
the business. Ithink supports the first modeling stage, which is known as rough
modeling, through Causal-Loop Diagrams, which offer heuristic models that do
not distinguish between the different types of variables and connections. A
Causal-Loop Diagram is then transformed into a flow diagram, using the
graphical simulation language. This second stage is where the actual analysis of
a process takes place and proposals for improvement show up. Finally, in the
third modeling stage, several scenarios with different settings can be run.
Changes to the diagrams are made easily so that the what-if analysis is not just
related to numbers but moreover to the business processes. Functional areas co-
operate so that the different pieces of the system make music.
Business Dynamics
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Case 3. A VMI Partnership
(adapted from Chaffey)
Retailers have long sought greater collaboration in their supply chains, but few
have managed to achieve it. One that has is Tesco, the UK’s largest grocery
retailer, which has built a reputation as one of Europe’s most innovative retailers
in its use of information technology.
As with many retailers, Tesco has long used electronic data interchange (EDI) to
order goods from suppliers and the network links almost all of Tesco’s 2500
suppliers.
The EDI system started operating in the 1980s and its use was initially limited to
streamlining store replenishment. In the 1990s, Tesco took its first steps on the
road to collaboration and began using its EDI network to help its suppliers better
forecast demand.
Most suppliers received EDI messages with details of actual store demand,
depot stockholdings and Tesco’s weekly sales forecasts.
According to Barry Knichel, Tesco’s supply chain director, this forecasting project
has been successful as average lead times have fallen from seven to three days.
‘Nevertheless, the information flow is strictly one way,’ he says. ‘We still do not
know the true value of this sales data because we never get any feedback.’
From the start of the 2000s, Tesco thus started its Tesco Information Exchange
(TIE) project in an attempt to achieve much more sophisticated two-way
collaboration in its supply chain. ‘This really was a big development for us,’ he
says. ‘The guiding principle was to combine our retailing knowledge with the
product knowledge of our suppliers.’
A large Tesco store may carry 50,000 products while a supplier will have at most
200. An important aim of the TIE project was thus to shift responsibility for
managing products down to the relevant supplier.
Suppliers pay from 500 Euro to 500,000 Euro to join TIE, depending on their
size. This then allows them to access the TIE web site and view daily electronic
point-of-sale data from Tesco stores. According to Mr Castillo, TIE lets suppliers
monitor changes in demand almost in real time and so gives them more time to
react. Besides this the lead times have fallen down further from three to less than
two days. ‘Before, Tesco’s suppliers would not have seen a problem until Tesco
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got on the phone to them,’ he says. ‘Now, it is the suppliers who get on the
phone to Tesco and they can see much earlier on if a product is not selling well.’
The data can be analyzed in a number of ways to allow suppliers to see how
sales perform by distribution center, by individual store or even by TV region -
important for promotions.
According to St Ivel, one of Tesco’s bigger food suppliers, TIE has saved 30 per
cent of its annual promotional costs.
About 2400 suppliers, representing about 95 per cent of Tesco’s business, are
using TIE today. A collaborative data module aims to allow ‘seamless’ planning in
which the planning data on the screen is jointly filled in by both retailer and
supplier. Mr Knichel sees this as radical change for the retail industry as
suppliers and retailers have traditionally worked to separate agendas. He feels
TIE has much potential to streamline Tesco’s supply chain and to help suppliers
improve their service levels and promotions. But retailing is a traditional industry
and many suppliers are set in their ways.
‘Only four suppliers have fundamentally changed the way they work as a result of
TIE. Nevertheless, they can bring products to market much faster than any of
their competitors,’ he says.
Questions
2. What may be the disadvantages of TIE for Tesco and/or the suppliers?
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Case 4. Global Flower Value Chain
Innovations, trends in the global flower value chain
FloraHolland is the central institution in the world wide flower trade and
distribution (www.floraholland.com). Information technology plays a critical
role in shaping competition in the industry, competition with other auctions but
also with suppliers and growers who have possibilities and reasons to go
more “direct”.
IT directly affects the value networks. When IT was not well adopted during
the 1990s at FloraHolland, at that time Aalsmeer and Naaldwijk, for online
purchasing and sales, a competitor came up led by the East African Growers
association. This competitor, allowing online auctioning through the so-called
TeleFlower Auction, posed a real threat to the Dutch auctions. Finally the
Dutch auctions had to allow foreign growers participating in the auction and
giving more facilities to buyers, for instance allowing them to trade in different
halls and online. This implied huge investments in technology and change of
work processes. Finally Floraholland and its provider Auzcis were able to
jointly succeed and even export the auction model which is often used as a
standard. The model was exported to Brasil for instance an auctuion called
Holambra.
The flower industry has been one of the leading industries in the Dutch
economy. Since the middle of the 1970s, the production and distribution of cut
flowers have burgeoned. Growers are typically family businesses that grow
flowers in specialized greenhouses, heated and lit by the country's abundant
supply of natural gas to create an ideal climate for growing flowers.
Dutch growers over the years have been facing increasing competition for the
lucrative European markets from low-cost foreign competitors such as Kenya,
Spain, Israel, India, and Colombia. While Dutch growers experience
increasing land costs, environmental regulations and political trends to reduce
subsidies for gas prices, the foreign competitors have lower labor costs, fewer
environmental regulations and lower trade tariffs. The global diffusion of
agricultural technologies and cheaper air transport make international growers
more potent competitors. In response to these economic pressures, Dutch
growers have shifted their product mix to include high value-added flowers
that serve year round "impulse" buyers, in contrast to just serving the
"occasions market (others have merged, moved to other countries and quite
many have placed importance on all sorts of innovations - JS). Buyers for
various wholesalers and retailers participate daily in the Dutch flower auctions
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to purchase flowers which are then repackaged and resold to end-consumers
or retail stores. As supermarkets and large retail store chains have become
outlets for flowers, buyers purchase larger volumes and are becoming more
sophisticated in coordinating purchases across different auctions. There are
also economies of scale in the purchase and distribution of flowers, leading to
greater buyer concentration.
The auctions constitute a critical part of the trading process that begins when
growers harvest the flowers. Here is a typical example, also from Kambil and
Heck.
Growers harvest roses for export to the United States by mid morning on any
given day. By mid afternoon, machines will have sorted the roses by as many
as 200 varieties, and by the length of the stems. These roses are gathered,
labeled for quality, and packed in uniform plastic tubs for transport. By 10 PM,
the flowers arrive at the auction house where they are placed in cold storage
overnight. The next morning at 4:30 AM, they are transported to the collection
hall, inspected, assigned lot numbers, and assembled onto "stapelwagens" or
uniform carts for transport into the auction hall. The stapelwagens are then
towed into the auction halls where their contents are auctioned, beginning at
6:30 in the morning in auction rooms with up to 500 buyers (note that today
some clocks are virtual and stapelwagens do not need to come into the hall:
buyers in these halls do not even see the flowers -JS). The computerized
auction clocks in the room provide the buyers with information on the grower,
product, unit of currency, quality, and minimum purchase necessary (buyers
can also trade online or simultaneously in different rooms). See
http://www.aucxis-etrade.com/nl/case-studies/projectieveilen-te-floraholland.
Once the auction is completed, each lot of flowers is tagged with a computer
print out of the sale and distributed to the buyer's area in the auction house
where they are repackaged and boxed for air or land transport. Flowers
exported to New York are transported on a special eight-hour flight, which
departs Schiphol airport at 7:10 p.m. and arrives in New York at 8:10 p.m.
local time. The cargo is then unloaded, inspected, cleared by customs and
shipped to nearby warehouses or to other wholesalers for distribution the next
day. Thus roses from an Aalsmeer greenhouse (nowadays: from Kenya and
other East African countries - JS) can be sold in New York within 48 hours
after they are cut. Similarly, redistribution to other European countries by land
occurs within 48 hours. Timing is crucial as the product declines in value
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towards zero within 10-12 days after the harvest. See the distributed video as
well.
Many new technologies are emerging which can affect how FloraHolland and
other parties in the global supply chain conduct business. FloraHolland and
others have to decide if they can change the way they are doing business as
they respond to emerging new competition in the marketplace. How are value
chains affected?
Next, they have to consider what applications will be needed, which ones will
give them a competitive advantage or which need to be there out of
competitive necessity. To what extent can IT be an answer to the problems?
What are the IT strategies to be followed to succeed in the industry? What
associated changes need to be made. Not only FloraHolland is challenges,
other players as well : buyers, growers (local Dutch and foreign) and third
parties (for logistics, quality control, technology, freight forwarding, inspection,
etc.) and even governments are faced with similar questions.
Before the second world war, cut flowers were grown near markets. Later,
improved varieties and better transport allowed growers in southern Europe,
Israel, and parts of Africa and South America to supply northern European
and American markets. What was once a seasonal business was transformed
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into a year-round industry: roses became a Valentine's Day fixture. And Dutch
firms took on a special role as their norms for everything from bucket sizes to
environmental certification were adopted worldwide.
But as new competitors emerge in other parts of the world, the Netherlands'
flower auctions need to team up in order to compete, Mr Teelen believes.
Flower centres are emerging in Dubai, Tel Aviv, Kunming and elsewhere--
many of them closer both to producers and to promising new markets. And
big retailers such as Wal-Mart and Omega have started buying flowers
directly from tropical growers.
Even so, the auctions still serve a useful purpose by providing transparency in
pricing, says Amy Stewart, who surveyed the industry in a recent book,
"Flower Confidential". Price discovery at the auctions helps the entire industry,
she adds, yet it could be more efficient. As a result, she says, "the merger
makes a lot of sense."
It could also help the Dutch firms to maintain their position as the buying and
selling of flowers goes virtual. Around 80% of the stems sold at auction are
exported from the Netherlands, so the Dutch co-operatives have been
experimenting with a response obvious to traders in other markets: 15% of
auction turnover at Bloemenveiling Aalsmeer is now through remote bids, and
FloraHolland is testing video auctions of potted plants.
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c. Case “Arena Flowers”
Based on texts by David Chaffey, May 2013
The essence of the Arena proposition is to cut out middlemen and buys direct
through FloraHolland or from growers, so it can get great prices and the
flowers are exceedingly fresh. There are no ‘relay’ fees and, because of the
high stock turnover, they get fresh flowers in daily and these go straight to the
customer, rather than sitting in a hot shop window.
Arena offers free delivery on all products and were the first online florist in the
UK to offer FFP-accredited, ethically sourced flowers. That has been a good
‘unique selling point’ and enables Arena to offer something different from
other suppliers such as supermarkets.
Think of Holland and the enduring images that come to mind are windmills,
wooden shoes and…tulips. Tulips are not indigenous to the tiny nation. They
come from -- depending on whom you talk to – somewhere in central Asia,
Kazakhstan or Afghanistan, but were given to a Dutch merchant by the then
leader of Turkey in 1593. The name “tulip” derives from “tuliban,” the name of
the turban worn in the area, appropriate enough for the little bulbs.
Tulips have long been a force in Holland’s economy. Indeed, they were even
the source of the world’s first investment ”bubble” back in the mid-17th
century, when their value had escalated so precipitously that one bulb could
cost as much as a house, and thousands of people lost everything when, in
1637, a plant virus brought the whole value system crashing down. Cartoons
depicting this folly abounded in Dutch museums; artists added tulips to their
paintings as an aside commentary meaning “foolish.”
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Today the tulip continues as a mainstay of the country’s economic life, but it
plays a much more important role as the cornerstone on which Holland’s
leadership as the largest purveyor or plants and seeds in the world is built. It
all takes place at FloraHolland, the world’s largest flower auction, where today
more than half of the world’s flowers move from grower to distributor and then
on to you, the retail customer. It is indeed Holland's "Wall Street for Flowers."
The auction works in reverse: Rather than bidding up the price, Royal
FloraHolland’s auction bids down. The bidding system is based on a clock
that runs backwards: Bidding starts at 1 Euro and goes lower; buyers stop the
clock at the price they want to pay and then advise how many plants they
want. The average price for flowers between 2011 and 2014 was 22 cents; for
house plants about 1.60, and for garden plants 93 cents. Then the clock
resets. The process moves at lightening speed: In the time it takes you to
read this paragraph, Royal FloraHolland would have sold perhaps ten lots of
flowers.
To the casual observer, it all seems quaint in an efficient sort of way: bidding
done on computers, more than half of the auction participants doing their
bidding off premises, and yet here are the actual flowers right under your
nose. Within hours they could be in a bouquet on your dining room table. And
flowers are such an all-purpose commodity (wedding, funerals, birthdays,
Valentine’s day…) they practically sell themselves.
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But that’s another surprise: The flower business and Holland’s leadership
position in it has been “disrupted” by the Internet, the economic crisis ,
competition from new low-cost growers, and changing consumer tastes.
Shortly after 2009, Royal FloraHolland’s consistent growth trajectory – on the
up since the cooperative was founded in 1911 – ground to a halt.
The report crystalized and quantified the problems the floriculture community
had known for a while and was already addressing: Lucas Vos, Chief
Commercial Officer of Maersk shipping was hired as CEO at Royal
FloraHolland effective January 1, 2014. Vos lost no time in creating an action
plan to overhaul Royal FloraHolland – reaching out more to the end
consumer, boosting marketing efforts, cutting costs and streamlining logistics.
Royal Flora Holland says one of its goals is to facilitate a 20% increase in the
consumption of flowers and plants in Europe. So far the results seem
promising. Last year the European market for flowers and plants grew 0.5% to
32.4 billion euros. It was a steep climb: 2013 saw the worst of the economic
crisis, when consumption value dropped below 31 billion euros.
After-tax profits for Royal FloraHolland in 2014 were 9.6 billion euros vs. the
15.6 bilion peak in 2011.
Emerging markets such as Brazil Mexico, China, and India are driving growth
– despite
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becoming flower producers themselves. Thus far, increasing domestic
consumption fueled by higher incomes creates enough demand to keep the
international market from becoming flooded despite this new production.
The Royal FloraHolland financial report shows operating costs have come
down, but not without a price. When the company announced it would cut 200
jobs in 2014, in Vos’s first months on the job, workers went on strike. Vos held
his ground and began working on the Royal FloraHolland “2020 Plan,” to
strengthen the organization and keep it relevant. Steps include increasing
quality control, managing supply and demand more efficiently, providing more
services to suppliers and more information to retail customers about the state
of the global flower market, and exchanging information.
It is a tall order, but there are other benefits, and not just to the world of
flowers, as these plans proceed. A market as large as this can have an impact
on sustainability – on labor, on the chemicals used in growing, on
transportation and CO2 emissions – which will in turn create beauty beyond
the garden walls.
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purchased by 2,500 clients. This is shown in the Royal FloraHolland annual
report 2017 that was published on 24 April 2018.
Last year saw a shift from regular auction sales to direct sales between
growers and clients. In 2017 regular auction sales represented 43.7% of the
total turnover, whilst 56.3% came from direct sales - direct sales of cut flowers
show an increase of 5.7%. Houseplants and garden plants increased by 3.1%
and 11.9%, respectively.
Steven van Schilfgaarde, CEO Royal FloraHolland said: “In 2017, we
committed fully to digitisation on the one hand, with the launch of our digital
marketplace Floriday as the most important milestone. We are committed to
reinforcing the clock. I am convinced of its power."
FloraXchange
Sustainability is an integral part of the auction’s annual report this year. Royal
FloraHolland says it works continuously on the improvement of its own
sustainability profile and plays an important role in improving supply-chain
sustainability and transparency, and Royal FloraHolland is one of the partners
in the Floriculture Sustainability Initiative (FSI). FSI's ambition for 2020 is to
have 90% of the members' flowers and plants production or trading be done
sustainably. In 2017, that percentage was 33% for flowers and 53% for plants.
Questions
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4. Why can a true online florist like Arena serve more customers than
a bricks and mortar florist?
5. How does Arena add value to the product?
6. How is Arena able to reach higher service levels than the florists
who have gone online in the Fleurop network (www.fleurop.nl)?
7. Why is Arena not merely focusing at selling more flowers, but rather
at increasing AOV?
8. From the perspective of a large florist (a classical one and a
modern one like Arena): what are the advantages of sourcing from
the FloraHolland’s Auction as compared to a downstream
intermediary (wholesales)? On what factors does it depend? Any
disadvantages?
9. Nowadays technology can easily connect a florist to growers, is it an
option for a florist to buy (source) directly from growers (e.g. in Holland,
e.g. in Kenya)? What are the challenges?
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. The 787 dream was to systematically reduce development time from typically six to
four years and cut associated costs from around $10 billion to $6 billion. The result
has been cataloged more like a nightmare. The project is reported to be billions of
dollars over budget and three years behind schedule.
Dell model – to reduce financial risk by 80% outsourcing increased risk. Did not
anticipate the risk involved.
Outsourcing to sub-contractors
Toyota strategy
Shorter span time
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