降低运费的绿带项目.ppt

Project Title : Freight Charge Reduction 项目名称 : 降低运费 Green Belt : Maggie Xu 许玉梅 Division : Shanghai Morgan Carbon 上海摩根碳制品有限公司 Location : Shanghai. China. Asia 亚洲. 中国. 上海 Sponsor : Ray Xu 徐穗 Master Black Belt 黑带大师: Jiang Ting Feng 蒋霆峰 Project Champion 项目盟主: Li Shuxun 李叔恂 Deployment Champion 推进盟主: Li Shuxun 李叔恂 Executive Champion 行政盟主: Simon Hussey 西蒙 哈赛 Team Members : SMC：Ray/Adrian 徐穗 / 张捷 ECS：Crow / Ada 朱江/ 罗静芬 Forwarder：FedEx-Julie Wu / Emery-Sam Liu / Shining-Grace Shi 联邦-吴建敏 / 伊美利-刘伟华 / 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.,项目背景 Project background:,DEFINE,确立项目范围 Establish Project Scope,我们从哪开始？ 问题是什么？ 问题的量是什么？ 相关的财务问题是什么？,明确问题描述:运费过高 明确问题改进目标:降低票数最多的运费 完成项目的期望时间:2004年8月30日 指定项目成员:徐穗/张捷/朱江/罗静芬/吴建敏/施佩佩 过程负责人及组长: 徐穗 管理层的承诺: 全力支持,精确的问题描述（焦点）:同货运公司之间的合作无协议 * 过程的缺陷要点:进口/出口运费均偏高 * 明确的目的（目标）:同货运公司签定协议 * 合理的范围: 设定目标价，要求提供门到门的服务 * 很好地确认过程主人:许玉梅 * 管理层的承诺（资源）全力支持,过程专家 许玉梅 步入过程，记录实际的过程：对每一笔运费进行记录 缺陷数据 T-test均值数据为$8.17,过程图PMAP已有 过程专家许玉梅,* 过程图 PMAP已完成 * 过程改进行动，时间，职责 计划2004/4月起采取改进措施,* FMEA FMEA已完成 * 列出潜在的关键因子: 同货运公司之间的协议 * 过程改进行动，时间，职责 均已列入FMEA的推荐措施,现有过程是怎样？ 过程步骤是什么？ 每个过程的输出是什么？ 每个过程的输入是什么？ 过程的哪里产生了缺陷？,过程的潜在失效模式是什么？ 怎样对潜在的失效模式量化？ 哪些过程应该重点关注？,基本过程 Baseline Process,现有过程能力怎样？ 客户的期望是什么？ 过程的历史表现如何？,基本信息 -供应商数据: 任用货运公司，不考虑到付运费 -过程数据:运费单价不一致，均值特别高 -客户数据:任用报关行，价格高 客户的规格指标: 对不同的运输方式，同不同的货运公司签定协议价格 供应商的规格指标 订价高，利润最大化,* 控制图所需的数据： -时间效果: 6月份完成测量 -普通原因比特殊原因:未发现特殊原因,项目困难主要来自普通原因 -过程能力: T-test分析显示过程特差 * 期望的财务过程改进利益是什么？运费下降,节约成本.,确定过程失效模式FMEA ID Process Failure Modes,将过程特性化 Characterize Processes,DEFINE,产品样本：未改进前的运费 工作人员：许玉梅 测量装置：用KAPPA对运费进行分析,因果战略和设计：Y=f(x) 样品: 运费 时间： 2004/04 因果分析：找出Y和x之间的函数关系,运行因果确认的结果：同供应商之间达成协议 时间：2004/05-2004/08 样品 运费,关键过程变量：运费单价 过程负责人：许玉梅 控制策略：文件化,* MSA: KAPPA * 评估测量系统的变差：KAPPA值0.7，可以接受 * 过程改进的方向 经过双方彻底交流，测量值可接受,* 因果结果和分析：影响运费的关键因素为供应商/运费底价/重量(体积)/票数/谈判 * 过程设置的改进： 按T-test结果改进 * 理解变量之间的相互作用；改进运费，以上因素缺一不可,* 改进过程的设置： 按T-test结果改进,* 控制计划：运费控制计划 交流形式和时间：同组员沟通、2004-08,关键的输出/变量是什么？ 输入变量之间有哪些相互关系？,对关键输出进行衡量吗？ 我们能否对关键输出进行测量？ 现有的测量变差是多少？ 客户的测量系统能力如何？,最好的过程设置是什么？ 我们能否确认这最好的过程？,我们怎样维持并控制过程的改进？ 怎样在公司内，向客户及供应商 交流过程的执行？,实施过程改进 Implement Process Improvements,评估测量系统 Measurement Systems Analysis,确定关键变量 ID Critical Variables,控制/维持过程改进 Control/MaintainProcess Improvements,下一轮持续改进,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),关键输入 Cr:关键输入 C :可控输入 N :噪音 S :标准作业指导,DEFINE,Process Map IMPORT,发订单,订单确认,供应商生产,货运公司订价 及货运,码头卸货,清关,运输,N: 订单,N: 其它客户价/SMC历史价/价格波动 S: 历史生产周期 C: 当前生产计划,N: 原材料 C: 生产计划,N: 燃油价格 C: 运输成本 N: 货物 Cr: 我方运输总量 N: 发票/箱单/运单 N: 规模效应,C: 装卸成本 N: 运输费,C: 人工 C: 单证 N: 海关,C: 司机 C: 卡车 C: 运输成本,品名/数量 要求交货期/发运方式,单价 承诺交货期,产品实际交货期,货到目的港,卸货费,清关费,短途运输费,请购单,入库,Process Map EXPORT,生产,订舱,送货,报关,N: 订单 N: 图纸 C: 生产计划,N:订舱单,N: 货物 C: 司机 C: 卡车 Cr: 运输,N: 货物 C: 发票/箱单/核销单/报关单/报关委托书 N: 海关,产品,进舱单,货物进入海关监管仓库,放行,关键输入 Cr:关键输入 C :可控输入 N :噪音 S :标准作业指导,Quote to be obtained from forwarder when booking,订单,发货,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.,测量系统分析计划 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