operations flexibility in process industries - Roland Berger Strategy ...

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2A consumer goods producer uses a mixture of measures to dealwith volatile demandInterview example: Consumer industrySITUATION/CHALLENGEVolatile demand pattern …DemandTime… that is relatively predictableDemandTimeScenariosSOLUTIONClosecooperationwith thecustomerFlexiblemachine parkandproductioncontrolHR-Managementmeasures• Studies on market development and trends on aregular basis• For selected products customer forecast on weeklybases• For selected products only make-to-order• Flexible machinery• Set up APS to get overview on global [?] capacity• Nearly no change over times and nearly no yield lossesduring change-over• Flexible maintenance contracts with service provider(maintenance during time of low demand• Flex-time/working hours account• Job sharing (partly hob in production/partlyadministration)• Usage part time employees (5-20%) depending onproduction line to face huge volatilities in demand• Very "flexible" workers (e.g. students) for high peaks(up to 10%) "Hausfrauenschicht"Source: Roland Berger interviews, 200832Airbusinterview
3A consumer goods and a pharmaceutical producer use a four stepapproach to deal with fast growing local marketsInterview example: Chocolate industrySITUATION/CHALLENGEFast growing local markets…… that are relatively predictableDemandTimeScenariosSource: Roland Berger interviews, 2008SOLUTIONContractswith localdistributorsJointventuresAdditionalown salesorganizationAdditionalproductionplants• Supply of the customer in fast growing markets bydistributor• Distribution to the county is organized by chocolateproducer to secure fats delivery times• In several countries the chocolate producer has jointventures with local companies• If demand d in local l market is high h enough, own salesorganization id founded• Organization of whole distribution from the productionplant over the warehouse to the final customer by thechocolate producer• Build-up of additional production plants in the fastgrowing markets• Preferred option if business opportunity appears stableand needed quality standard can be achieved incountries• Often acquisitions are used for a fast increase of localproduction capacity33Airbusinterview
Page 1: OPERATIONS FLEXIBILITYIN PROCESS IN
Page 4: The study covers three process indu
Page 7 and 8: Eight trends in the pharmaceutical
Page 9 and 10: Six trends in the consumer goods in
Page 11 and 12: Participants of this study confirm
Page 13 and 14: Different flexibility types exist:
Page 15 and 16: 1 DEMAND FLEXIBILITYPredicting year
Page 17 and 18: 3 NETWORK FLEXIBILITYFlexible produ
Page 19 and 20: 5 BUSINESS PORTFOLIO FLEXIBILITYM&A
Page 21 and 22: Choosing the most suitable flexibil
Page 23 and 24: 2DEDUCT OPERATIONS FLEXIBILITYBusin
Page 25 and 26: 4MEASURE IMPLEMENTATIONDecisions re
Page 27 and 28: DBest practice flexibility levers27
Page 29 and 30: M&A FLEXIBILITY LEVERSWith regard t
Page 31: 1A manufacturer of pharmaceutical p
Page 35 and 36: 5A large consumer goods company fac
Page 37: 7The specialty chemicals company us

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