Krannert School of Management Sustainable Growth of EATON’s Electrical Sector Optimization of the Distribution Network Purdue University 1 What Are We Covering? StarTrek Consulting Team Problem Statement Recommendation Analysis Summary Q&A Purdue University 2014 Case Competition 2 Tiepoint Consulting Team Nick Grady Ayush Goel Dane Snyder Brian Fish MBA 15 Operations and Finance MBA 15 Operations and Business Strategy MBA 15 Operations and Finance MBA 15 Finance and Operations Purdue University 2014 Case Competition 3 Current Situation • 16 Customer Manufacturing Solution Centers • Over 10 Components Manufacturing Sites Nick Grady 2014 Case Competition 4 Problem Statement • High inventory level • Increased premium freight • Questionable sustainability Nick Grady 2014 Case Competition 5 Recommendation • Construct new warehouse in Wichita, KA • Decreased overall inventory • Decreased premium freight • Strategic placement for future growth Nick Grady 2014 Case Competition 6 Current Cost Analysis Shipping Modes as a Percentage of Total Orders for Selected Sites Shipping Costs: $5,189,791 1 • Standard Trucking • Premium Freight 0.9 0.8 Standard Trucking 0.7 0.6 0.88631 Premium Freight 0.5 0.4 $590,049 0.3 0.2 0.1 0.11369 0 Nick Grady 2014 Case Competition 7 Current Cost Analysis 4 Sites Considered: Shipping Cost Calculation Premium Freight as a Site Percentage of Total Orders Chicago-SAT 7% Chicago-SVC 12% Dallas-SAT 3% Dallas-SVC 17% Los Angeles-SAT 10% Los Angeles-SVC 9% San francisco-SAT 24% Order Order Origin Destination Distance Weight of Orders Average Cost/mile/lb Total Transportation Cost Chicago, IL 828 mi 50,290 $12,659 Fayetteville, NC $.000304 Total Annual Shipping Cost of Selected Sites: $2,385,434 Nick Grady 2014 Case Competition 8 Inventory Reduction Analysis Location-product combinations to pool % Premium Order of Total Order-By-Site 30% 25% 20% 15% • • • • • • • Chicago-SAT Chicago-SVC Dallas-SAT Dallas-SVC Los Angeles-SAT Los Angeles-SVC San Francisco-SAT 10% 5% 50% 0% of Total Premium Orders % Premium Order of Total Order-By-Site Dane Snyder 2014 Case Competition 9 Inventory Reduction Analysis Inventories of Common Stock-out CMSC's $2,000,000 $1,800,000 $1,600,000 $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200,000 $0 Chicago-SAT Chicago-SVC Dallas-SAT Mean Dane Snyder Dallas-SVC Los Angeles-SAT Los Angeles-SVC San franciscoSAT Safety Stock 2014 Case Competition 10 Inventory Reduction Analysis Safety Stocks of Individual vs. Pooled Inventory $1,600,000 $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200,000 $0 Total Individual Inventory Pooled Inventory Safety Stock Dane Snyder 2014 Case Competition 11 Cost Savings Analysis Assumptions: • • Shipping cost is average of costs provided @ $0.304/1000 miles/Lb After risk pooling LTL can be negotiated to FTL – Sensitivity analysis of the cost assessed by varying between 75% - 100% of the LTL cost Ayush Goel 2014 Case Competition 12 Cost Savings Analysis Shipping Cost Warehouse selection criteria: $2,000,000.00 • 300K Population • A positive growth rate region • Near to CMSCs with 50% premium freight $1,800,000.00 $1,600,000.00 $1,400,000.00 $1,200,000.00 $1,000,000.00 Sensitivity Analysis: $800,000.00 $600,000.00 $400,000.00 $200,000.00 $Phoenix Vegas Shipping Cost Ayush Goel Witchita • Three locations shipping costs were calculated • Wichita, KS was lowest costing with highest growth rate in population 2014 Case Competition 13 Cost Savings Analysis Shipping Costs Current Distribution Network 3,000,000 2,000,000 • Shipping cost are $2.4M • Frequent stock outs • High Days-On-Hand (DOH) 1,500,000 New Warehouse at Wichita, KS 1,000,000 • Shipping cost just $1.5M, half of older network • Low Days-On-Hand (DOH), uncertainty in demand is pooled • New growth region, opportunity for new CMSCs in central US 2,500,000 500,000 0 Current Network Shipping Costs Ayush Goel New Network 2014 Case Competition 14 Financial Feasibility Analysis Brian Fish 2014 Case Competition 15 Summary Brian Fish 2014 Case Competition 16 Have Doubts! 2014 Case Competition 17 Appendix Shipping Cost Savings Transport Cost Receiving from Warehouse Receiving at Warehouse Net $ $ $ Phoenix 1,293,434.30 $ 538,942.33 $ 1,832,376.63 $ Vegas 1,294,952.20 $ 567,155.76 $ 1,862,107.96 $ 2014 Case Competition Witchita 1,236,312.58 309,437.73 1,545,750.30 18