Biggest Challenges for Today s Supply Chains

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1 Hot Topic Report Biggest Challenges for Today s Supply Chains Supply Chain Consortium Benchmarking & Best Practices April

2 Table of Contents Introduction 3 Survey Demographics 4 Biggest Short-Term Challenges 7 Biggest Long-Term Challenges 20 Conclusions 21 Report Authors 22 2

3 Introduction The Biggest Challenges for Today s Supply Chains Report shines a bright light on the most significant short-term and long-term challenges that executives face today. To provide this insight, the report breaks responses down into the following categories: Private Equity (PE) Firms 3PLs Wholesaler/distributors Retailers Manufacturers Responses are segmented by industry in order for the data to be more applicable to specific industry groups. The information derives from direct comments from individuals to the survey questions, ranked from the topic area with the most comments to the least comments. Not all survey comments have been included in each category; only the highest rated topics are identified. To best utilize the report, read the comments on the page(s) that applies to you. 3

4 Survey Demographics Percentage of Survey Participants by Title 13.2% 28.9% SVP and Up VP 2.6% 55.3% Senior Director Director The survey was completed by high-level participants, including nearly 70% of respondents at the VP or SVP and above level. 4

5 Survey Demographics Percentage of Survey Participants by Industry 5.3% 5.3% Manufacturer 13.2% Retailer 47.4% Wholesale / Distributor 3PL 28.9% PE Manufacturers represented 57% of responses, followed by retailers at 29% and wholesale/distributors at 13%. 5

6 Survey Demographics Percentage of Survey Participants by Segment Consumer Products 7.9% 5.3% 5.3% 23.7% Industrial / Commercial Apparel 10.5% 13.2% 18.4% Food & Beverage Department and Discount Pharmaceutical 3PL 15.8% PE The largest industry segments of the survey were Consumer Products, Industrial/Commercial, Apparel, and Food & Beverage. 6

7 The topic areas with the most responses, and therefore considered to represent the greatest short-term challenges for supply chain leaders, are listed below. Costs: 22 responses Working Capital: 16 responses Talent/People/Labor: 14 responses Global Economy: 14 responses Software/Technology: 11 responses Demand Planning: 10 responses Supplier Relations and Compliance: 10 responses Supply Chain Network: 9 responses Disruptions: 6 responses Distribution Efficiency, Capacity, & Throughput: 6 responses Customers: 5 responses 7

8 Private Equity Firms Demand Planning Forecast accuracy and demand planning (2) Global Economy Software/Technology Talent/People/Labor Working Capital Slow U.S. economy recovery, foreign markets ERP implementation, supplier partner data integration Staffing levels, labor management Managing inventories to lower levels, lower inventory without sacrificing service The topic areas that present the biggest challenges for private equity firms are Demand Planning, Global Economy, Software/Technology, Talent/People/Labor, and Working Capital. 8

9 3PL Firms Costs Talent/People/Labor Software/Technology Labor costs, fluctuating fuel costs, real estate costs Talent development, hiring qualified management/engineers, local labor availability New software integration, WMS development Global Economy Expanding business globally (2) Capacity Transportation capacity (2) The topic areas that present the biggest challenges for 3PL firms are Costs, Talent/People/Labor, Software/Technology, Global Economy, and Capacity. 9

10 Wholesalers/Distributors Costs Working Capital Software/Technology Demand Planning Fuel costs (2), double-digit cost reduction, international freight costs Minimize excess and obsolete inventory, inventory reduction, days of supply Synchronize inventory data across supply chain, IT integration Meeting demand volatility, fluctuations in demand Customers Customer service levels (2) Imports and Customs Unexpected delays in customs, customs clearance lead time MH Equipment/Automation Customers want automated operations (2) The topic areas that present the biggest challenges for wholesale/distribution firms are Costs, Working Capital, Software/Technology, Demand Planning, Customers, Imports and Customs, and MH Equipment/Automation. 10

11 Retailers Talent/People/Labor Leadership development (2), keeping and/or getting fully staffed (2), labor management, labor management system Supply Chain Network Costs Supplier Relations and Compliance Working Capital Global Economy Distribution Efficiency, Capacity, & Throughput Expanding DCs (2), closing DCs/consolidation, network review, changing product flow Cost reduction (2), cost containment (2), fuel cost offset Vendor compliance, negotiating, restructuring buying teams, new sourcing and network Improving inventory turns (3), inventory management Global/international growth (3), supporting growth in Asia Space requirements, throughput requirements, unique product characteristics The topic areas that present the biggest challenges for retail firms are Talent/People/Labor, Supply Chain Network, Costs, Supplier Relations and Compliance, Working Capital, Global Economy, and Distribution Efficiency, Capacity, & Throughput. 11

12 Manufacturers Costs Fuel prices (2), product costs (2), cost reduction initiatives (2), transportation pricing (2), wage increases and inflation Working Capital Disruptions Supplier Relations and Compliance Demand Planning Global Economy Software/Technology (Continued on next page) Working capital reductions (4), short-term inventory balancing, inventory levels and discards, increased working capital turns U.S. port disruptions (3), severe weather (2), delays in delivery process Supplier stability/reliability (2), supplier lead time (2), supplier failures, subcontractors to tier 2 position Demand volatility (2), S&OP process, planning processes, accurate demand signals Europe economy/euro (2), consumer spending, fiscal cliff/debt ceiling, slow economic growth, economy-finding sales New ERP systems (2), systems upgrades, MRP proficiency 12

13 Manufacturers (Continued) Transportation Talent/People/Labor Supply Chain Network Rate prediction, trucking reliability, FOB pricing pressure Recruiting talent (2), labor shortage in China Create additional DC, warehouse number reduction, centralize DC The topic areas that present the biggest challenges for manufacturer firms are Costs, Working Capital, Disruptions, Supplier Relations and Compliance, Demand Planning, Global Economy, Software/Technology, Transportation, Talent/People/Labor, and Supply Chain Network. 13

14 Apparel Industry Costs Global Economy Supplier Relations and Compliance Demand Planning Sales Growth Talent/People/Labor Working Capital Costs and cost containment (3), FOB price pressure, rate prediction, container shipping cost Consumer spending, slow economic growth, weak Euro Supplier stability, vendor compliance, logistics services to new supply sources Forecast volatility, demand flexibility Sales growth, international growth Functional competence, development and retention of top performers Lowering inventory, increasing turns The topic areas that present the biggest challenges for apparel industry firms are Costs, Global Economy, Supplier Relations and Compliance, Demand Planning, Sales Growth, Talent/People/Labor, and Working Capital. 14

15 Consumer Products Industry Costs Working Capital Software/Technology Talent/People/Labor Demand Planning Fuel costs (2), international freight costs, product costs, wage increases and deflation, cost reduction Inventory reductions (2), inventory levels and discards, improving inventory turns, minimize excess and obsolete inventory Labor management system implementation, synchronized inventory data, IT integration Labor shortage in China, getting and keeping fully staffed, labor availability S&OP process, demand volatility Financial Performance/Budgeting Supply Chain Network Hitting aggressive budgets, shrinking margins Expand regional DCs, open additional DC The topic areas that present the biggest challenges for Consumer Products industry firms are Costs, Working Capital, Software/Technology, Talent/People/Labor, Demand Planning, Financial Performance/Budgeting, and Supply Chain Networks. 15

16 Department and Discount Industry Distribution Efficiency, Capacity, & Throughput Talent/People/Labor Ecommerce/Direct to Consumer Supply Chain Network DC space (2), seasonal product requirements, DC throughput Labor management, recruiting of skilled specialists, leadership development E-commerce requirements, multi-channels Closing of DC, supply chain network review Working Capital Inventory management (2) The topic areas that present the biggest challenges for Department and Discount industry firms are Distribution Efficiency, Capacity, & Throughput, Talent/People/Labor, Ecommerce/Direct to Consumer, Supply Chain Network, and Working Capital. 16

17 Food and Beverage Industry Supplier Relations and Compliance Disruptions Demand Planning Government Legislation/Regulatory Price/Commodity Volatility Supply Chain Network Supplier failures, supply reliability through Asia, new sourcing network Weather-related shortages, business continuity planning, delays in supply Demand forecast accuracy, demand fluctuations Trade bill legislation, government regulations Commodity volatility, raw material price fluctuations New network, warehouse consolidation The topic areas that present the biggest challenges for Food and Beverage industry firms are Supplier Relations and Compliance, Disruptions, Demand Planning, Government Legislation/Regulatory, Price/Commodity Volatility, and Supply Chain Network. 17

18 Industrial/Commercial Industry Costs Supplier Relations and Compliance Working Capital Demand Planning Total cost productivity (2), railroad pricing, reducing costs Supply management, lead time reduction, subcontractors to tier 2 position Short-term inventory balancing, increase working capital turns, inventory reduction Demand volatility, accurate demand signals The topic areas that present the biggest challenges for Industrial/Commercial industry firms are Costs, Supplier Relations and Compliance, Working Capital, and Demand Planning. 18

19 Pharmaceutical Industry Costs Global/Emerging Markets Working Capital Software/Technology Supply Chain Network Fuel costs, cost reduction initiatives End-to-end supply chain, emerging market growth support Working capital reduction, inventory reduction initiatives ERP implementation, IT integration Create additional DC, reduce number of warehouses The topic areas that present the biggest challenges for Pharmaceutical industry firms are Costs, Global/Emerging Markets, Working Capital, Software/Technology, and Supply Chain Network. 19

20 Biggest Long-Term Challenges The topic areas with the most responses, and therefore considered to have the greatest long-term challenges for supply chain leaders, are listed below. Costs: 24 responses Software/Technology: 15 responses Talent/People/Labor: 13 responses Global Economy: 12 responses Distribution Efficiency, Capacity,& Throughput: 8 responses Supplier Relations and Compliance: 8 responses Government Legislation/Regulations: 6 responses Supply Chain Network: 6 responses Demand Planning: 5 responses Sales Growth: 5 responses Transportation: 5 responses Flexibility/Predictability: 5 responses 20

21 Conclusions There is considerable overlap between the ranked order of the topic areas that were determined to be short-term challenges and those that were long-term challenges. Short-Term Challenges Costs Working Capital Talent/People/Labor Global Economy Software/Technology Demand Planning Supplier Relations and Compliance Long-Term Challenges Costs Software/Technology Talent/People/Labor Global Economy Distribution Efficiency, Capacity, & Throughput Supplier Relations and Compliance Government Legislation/Regulatory 21

22 SUPPLY CHAIN EXCELLENCE SUPPLY CHAIN EXCELLENCE Report Authors To learn more about benchmarking and best practices, additional resources are available to members through the Supply Chain Consortium: Qualified companies can join the Supply Chain Consortium s LinkedIn or Xing Group: Bruce Tompkins Executive Director Chris Ferrell Director 6870 Perry Creek Road Raleigh, NC (919) Office (919) Mobile 6435 Hazeltine National Drive Suite 105 Orlando, FL (407) Office (919) Mobile btompkins@tompkinsinc.com cferrell@tompkinsinc.com 22

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