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STRATEGIC CONFERENCE SYDNEY AUSTRALIA FEBRUARY 28, 2006 INVENTORY OPTIMIZATION BY DAN OLIVER
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Generating Plants Transmission System UTILITY System Distributor Customers Residential, Commercial, Industrial Directly Served Industries Interconnection Points
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11 fossil plants (59 units) 3 nuclear plants (5 units) 29 hydro plants (109 units) 4 combustion turbine plants (48 units) 1 pumped storage station 17,000 miles of transmission line Generating Facilities
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Win-Win-Win… Win for UTILITY Win for UTILITY Supplier Partners Win for UTILITY Customers 158 power distributors 62 direct serve industries Over 8 million people in an 80,000 sq mile service area Public users of land and recreational facilities Communities with economic development assistance CUSTOMERS SERVED CUSTOMERS SERVED
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A key part of the Supply Chain challenge continues to be the change from a price focus to a Total Ownership Cost (TOC) focus: TOC Focus PURCHASE COST Actual Opportunity or “TOC” (The whole iceberg) Perceived Opportunity (Above the Waterline) FORECASTING: equipment life/failures system improvements system capacity technology drivers TECHNICAL: reliability standardization design / scope clarity configuration management PROJECT JUSTIFICATION: project justification criteria business unit alignment TVA-wide ROI analysis INVENTORY PRACTICES: inventory ownership (SMI, consignment) risk mitigation re-deployment of useable RETIREMENT PRACTICES: disposal cost secondary users OPERATIONAL PRACTICES: install & support costs maintenance costs capacity utilization training costs CONTRACTING: TVA leverage potential technology convergence re-bid frequency
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TYPICAL INVENTORY SITUATIONS DESIRE TO REDUCE SIGNIFICANT CAPITAL INVESTMENT IN INVENTORY CONCERN FOR BALANCING INVENTORY WITH RELIABILITY DESIRE TO CONTROL FUTURE INVENTORY GROWTH CONCERN FOR COMPLIANCE TO SARBANES OXLEY
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TYPICAL REASONS FOR INVENTORY GROWTH OVERBUYING FOR MAINTENANCE OR CAPITAL IMPROVEMENTS CANCELLED OR DEFERRED MAINTENANCE RETURNS AFTER COMPLETION OF WORK ADDITION OF NEW ITEMS INCREASES TO EXISTING MIN/MAX’S INCREASED PRICES
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PROGRAM ELEMENTS STRATIFY INVENTORY DATA IDENTIFY APPROPRIATE STRATEGY FOR EACH INVENTORY CLASS ESTABLISH TARGETS IMPLEMENT PROPOSED ALGORITHMS IMPLEMENT EACH STRATEGY TRACK RESULTS
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TYPICAL STRATIFICATION EXAMPLES CLASSIFICATIONLOCATIONCOMMODITY DOLLAR VALUE OVERSTOCK/SURPLUS SLOWMOVING – NO ISSUE IN X YEARS
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PROGRAM SUCCESSES $147M REDUCTION OVER 5.5 YEARS SIGNIFICANT CASH FLOW IMPROVEMENT SUCCESSFUL IN DIVERSE MRO INVENTORIES NO IMPACT TO OPERATION AND RELIABILITY
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INVENTORY OPTIMIZATION HIGHLIGHTS OBTAIN SENIOR MANAGEMENT BUYIN PERFORM INVENTORY ANALYSIS STRATIFY INVENTORY SET INVENTORY REDUCTION TARGETS TRACK PROGRESS COMMUNICATE TO ALL LEVELS OF ORGANIZATION CELEBRATE SUCESSES
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Months Supply - Active Browns Ferry Sequoyah Watts Bar NSI
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Outstanding On Order Net ROP/ROQ Changes
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INVENTORY PERFORMANCE FY02 GROWTH REDUCTIONSTRATEGIES 13.867M 13.196M October 2001 Beginning Inventory $100.072M September 2002 Ending Inventory $99.401M FYTD 1358 GROWTH DRIVERS Planned Work Receipts Non-Inv Planned Work Receipts Inv Initial Stock REDUCTION DRIVERS Shared Inventory ROP/ROQ Reduction Dollars ($000) Writeoffs Adjust- ments Normal Receipts
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756 INVENTORY PERFORMANCE FY02 September 2002 Ending Inventory $28.686M October 2001 Beginning Inventory $29.106M GROWTH REDUCTIONSTRATEGIES 7,184K 6,764K FYTD 756 1358 INVENTORY PERFORMANCE FY02 September 2002 Ending Inventory $23.378M October 2001 Beginning Inventory $23.473M GROWTH REDUCTIONSTRATEGIES 2,864K 2,769K FYTD 756 1358 GROWTH DRIVERS Planned Work Receipts Non-Inv Planned Work Receipts Inv Initial Stock REDUCTION DRIVERS Shared Inventory ROP/ROQ Reduction Dollars ($000) 756 1358 756 1358 GROWTH DRIVERS Planned Work Receipts Non-Inv Planned Work Receipts Inv Initial Stock REDUCTION DRIVERS Shared Inventory ROP/ROQ Reduction Dollars ($000) 1358 INVENTORY PERFORMANCE FY02 September 2002 Ending Inventory $33.053M October 2001 Beginning Inventory $33.136M GROWTH REDUCTIONSTRATEGIES 5,758K 5,675K FYTD 756 1358 756 1358 756 1358 GROWTH DRIVERS Planned Work Receipts Non-Inv Initial Stock REDUCTION DRIVERS Shared Inventory Adjust- ments ROP/ROQ Reduction Dollars ($000) Normal Issues Planned Work Receipts Inv INVENTORY PERFORMANCE FY02 GROWTH REDUCTIONSTRATEGIES 73K 0 K October 2001 Beginning Inventory $14.357M September 2002 Ending Inventory $14.284M FYTD 1358 GROWTH DRIVERS REDUCTION DRIVERS Shared Inventory Dollars ($000) Adjust- ments Adjust- ments Writeoffs Normal Receipts Writeoffs Normal Receipts Adjust- ments Normal Issues Writeoffs
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FY05 Materials Indicators March 2005
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SERVICE OFFERINGS BENCHMARKING BILL OF MATERIAL DEVELOPMENT INVENTORY DATA ANALYSIS PHYSICAL INVENTORY SUPPLIER MANAGED INVENTORY INVESTMENT RECOVERY WAREHOUSING MATERIAL STANDARDIZATION PROCEDURE DEVELOPMENT
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Rev. 6/6/05 INVENTORY OPTIMIZATION SUPPLIER MANAGED INVENTORY REVERSE ENGINEERING PROCEDURES SUPPLY CHAIN INVESTMENT RECOVERY POOLED INVENTORY INVENTORY OPTIMIZATION MODEL SARBANES OXLEY SHARED INVENTORY MATERIAL STANDARDIZATION KPI’S GOALSANALYSIS RATIONALIZATION BILL OF MATERIAL
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