Tackling Shrinkage to Improve Your Bottom Line Breakout Session Shrinkage Working Group ECR Europe Annual Congress, Brussels May 2004 Welcome Colin Peacock The Gillette Company Co-chair, Shrinkage Working Group Seminar Overview • Purpose – Enthuse the ECR community about the ECR shrinkage reduction methodology • Objectives – Illustrate retailer & supplier collaboration – Promote the ECR Approach – Provide new knowledge Agenda • • • • • • • • Introduction B&Q & Plasplugs Case Study ECR Shrinkage Survey Sainsbury’s & Menzies Case Study Key Performance Indicator Research Makro & Gillette Case Study Wrap up Q&A Designing in Solutions Eddie Joyce, Plasplugs Gill Yardley, B&Q B&Q • Biggest home improvement retailer in the UK • Employs over 36,000 people • Turnover last year €5.7 billion • Profit €546 million • 1998 B&Q merged with Castorama to become largest DIY Retailer in Europe • 1999 B&Q opened it’s first store in Shanghai Plasplugs Fixings Sharpening Systems History: Founded 1970 in the UK Family owned Brand Values: Leadership, Quality & Innovation Employees: Over 350 world-wide Turnover: Circa €59 million pa for the group Tiling Tools Knives & Blades Old Packaging B&Q – Reasons for Change • Sales good – yet room for category growth • Industry standard packaging - opportunity to improve • High shrinkage (10%+) due to damages and theft • Environmental compliance • Space efficiency – packaging space hungry • Requirement for suppliers to source tag • Opportunity to reduce Environmental tax levy • Customer wants to touch and feel the product Plasplugs - Reason for Change • • • • • • Improve visual display Reduce returns Introduce hidden source tagging Reduce dependency on third parties Improve tactile nature of packaging Desire to strengthen market leadership – Innovation and differentiation – Add value to product Old Packaging The Process • Both companies around the table to agree requirements • Plasplugs CEO involved from conception to delivery • Support from B&Q Sustainability Team and Commercial team • Solution evolved over period of time Evolution of Packaging Blister, Card & Adhesive Evolution of Packaging Blister Entrapment Evolution of Packaging Blister-less - Only Card Evolution of Packaging Packaging Free Plaspak Demonstration Old V’s New Tile Edge Nibblers Old V’s New Quik Tiler Old V’s New Tile Files Old V’s New Tile Scribe Old V’s New Tile Rack The Benefits of Collaboration • • • • • 50% reduction in shrinkage 33% increase in sales (€1.6M retail) Space created raised sales further €1.5M Customer can touch and feel product Secondary use of packaging: – Customers perceive this as ‘added value’ – Reduction in environmental levy Additional Benefits to Plasplugs • Design innovation has led to patented design solution • Return on investment within 18 months • Packaging deliveries now minimal • Plasplugs are at the cutting edge of innovative packaging solutions B&Q Tiling Accessories Display In Summary By innovation and collaboration benefits have been seen by both Plasplugs and B&Q. Key Benefits • • • • Reduced shrinkage and stock loss Enhanced presentation of the product Better control of costs Maximised space and profit per square metre 2nd ECR Shrinkage Survey Adrian Beck University of Leicester Background and Methodology • Last survey in 2000 • Need for a new benchmark • Definition of shrinkage – External Theft – Internal Theft – Process Failures – Inter-Company Fraud • Stock loss calculated at retail prices Background and Methodology • 26 countries surveyed (21 last survey) • 250 retail companies and 44 manufacturers/suppliers contacted • Total FMCG sector valued at €1,004 billion • Sample represents 13.7% of retail companies with a combined turnover of €137.2 billion Topics Covered in the Survey • • • • Counting the cost Location of the problem Extent of co-operation Measures used to tackle shrinkage Counting the Cost Sector Value (€ billions) Retail % of sales 1.84 Manufacturer 0.57 5.7 Total 2.41 24.2 18.5 Counting the Cost • Total loss equates to: – €66 million per day – €46,000 per minute (€4.1 million for this seminar!) The Retailing Shrinkage Iceberg 49% 51% Unknown Loss €9.5 billion Significant increase in known loss Location of the Problem 24% 5% 71% Manufacturer Distribution Retail Distribution Retail Stores €5.7 Billion + €1.2 Billion + €17.3 Billion = TOTAL €24.2 Billion Causes of Retail Stock Loss InterCompany Fraud 7% External Theft 38% Process Failures 27% Internal Theft 28% Retail Company Co-operation Security/Loss Prevention Store Mangt Board of Directors Auditing Supply Chain Mangt Logistics Finance Human Resources IT Dept Buying Legal Dept Planning and Design Marketing 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% Per cent High Involved Regularly Involved Hardly Involved 100% Spending on Stock Loss Measures Value Per cent Contract security staff € 950 million 33 In-house security staff/loss prevention/audit team € 419 million 14 Electronic tagging systems € 370 million 13 Closed circuit television € 298 million 10 Intruder alarm systems € 182 million 6 Cash protection equipment: safes, caches € 170 million 6 External security measures: shutters, bollards, fences € 164 million 6 Staff training on stock loss € 151 million 5 External audit companies € 44 million 2 Specialist display equipment € 29 million 1 Other € 133 million 5 Total € 2.9 billion 0.29 Causes and Spending on Shrinkage 60 Spending 60 Cause 50 40 38 30 27 28 26 20 10 9 4 7 0 External Internal Process Inter Company Other Survey Highlights • Companies that: – have a corporate policy – prioritise stock loss – provide bonuses for good stock loss results – have good intra-company co-operation – carry out shrink reduction projects… … have lower levels of shrinkage For a copy of the final report contact: Adrian Beck: bna@le.ac.uk WELCOME The UK Magazine Market An Insight Into Shrink David Morton Chris Price 25th May 2004 EXECUTIVE SUMMARY Aims & Structure A story about addressing SHRINK In the UK Magazines sector Sector complexity .. Process Issues How working together with wholesalers achieved results How Sainsbury’s managed to reduce shrinkage by 25% Explain how shrink on News & Magazines is a broader Industry issue Industry-wide approach .. Results .. €3m+ Approaches, Learning's & Blue Book The UK Magazine Sector The Magazine sector is worth €2.5 Billion Euros per year Publishers Wholesalers MD WHS DN Retailers Consumers LARGE Medium Small Ind 10 Main Publishers 3,000 Titles 160 Categories 55,000 3 major 5 Independent •Small number of big players 100+ Depots •Big number of small players Menzies Distribution - The Facts International services group .. time critical logistics: T/O €1.8bn Newspaper & Magazine distribution (UK) .. 4,000 employees 1500 van routes .. Every morning To 22,000 retail outlets .. From 30 depots 520,000 lines / 24 hours Unsolds scanned every day. JIT .. Cross Dock .. Consolidation .. & .. Reverse Logistics Sainsbury’s – The Facts Sainsbury’s stores sell over 1200 magazine titles A UK Market share of 5.5% Top 100 titles count for 74% of turnover Losses running at over 6% of sales WE HAD A PROBLEM! Sainsbury’s - First Steps - Alone Initial internal review : Complex area .. Not main focus of Supermarkets Inconsistent Store Procedures High level of ‘Rejected Returns Credits’ (Sale or Return) Wholesale supplier input .. End to End process You will see . . How ECR provided the “introduction” agency You will hear. .How Sainsbury’s were not alone The Sector The Publisher & The Product The Publisher Determines look, feel, & quantity ‘created’ Places (Pushes) into the market .. advertisers, not just sales Sale Or Return … reverse logistics The Product Each issue uniquely ‘created’ ..new barcode Magazines are not like tins of beans. The ‘Creative’ mix means risk of: Poor attention to practical detail … Product Challenges £2 €2.90 £1.75 €2.55 Product Challenges Disney and Me PC Gamer Presents Sector Tensions & Shrink Market Tensions !!! Shrink hit the Industry agenda late 2002 … and went TOP! Retailers clear… “It’s Publishers’ and Wholesalers’ fault”. Publishers clear…. “No it isn’t” Wholesalers …. The meat in the sandwich! Industry-wide collaborative project group formed Establish .. Define .. Recommend .. But an uneasy background! End-To-End Industry-Wide Shrink Initiative A Meeting of Minds? ……. More a Clashing of Heads! Deal in Facts …. Not Noise! Definition … Principles … and Method ECR Blue Book … Recipe ! Our Principles All committed .. Solve .. Don’t just shift the problem! Overall structure .. prioritise Industry Shrink Group Modus Operandi Adopt a process 0.Wake Up Up Research Map key processes, together Establish interdependences Highlight pressure points Measure .. Identify costs Identify solutions .. Prioritise 1. Plan 6. Evaluate Evaluate & 2.Map 2. Map & Measure Measure 5.Implement 5. Implement 3. Analyse Good News (of sorts) We were not alone .. Shrink affects all supply chains 4. Develop 4. Solutions End-To-End Roadmap Fishing for Detail Build a structure to identify, log & relate ‘points of failure’ Wholesaler supply process inadequate van lighting poor accountability Product characteristics bar code W/S misdelivery printing error Cover price/file mismatch other live misleading product title supplement Title description/ cover mismatch poor cover positioning wrong info on file Too much product supplied W/S miscount W/S misplace pick single delivery (not SBR) local v H/O range disjoint non-standard shape/size W/S mis label full/odds bundle identifies wrong issue W/S mispicks over/under picks wrong title poor accountability Incorrect price H/O file information updates first time title has appeared price variants with same bar code h/o information update late late info. from publisher unauthorised titles /excess copy supplied insecure back cover mount door area removal In store staff lack of procedure or facts stockroom title v cover Rejected delivery(unacceptable poor transit condition) packaging Collusion at back door In transit W/S to retail collusion between driver another customer/outlet printer/ publisher/ carrier to W/S poor security Robbery in depot W/S or publisher planned or opportunist Theft poor product covermount/ packaging with consumer 'sweethearting' staff abuse honesty box display consumers Fraudulent claim of short/ non delivery Lack of audit parcel theft by another Individual physical theft product not returned staff awareness/ process Booked-in against wrong shop a/c shop save/ forecourt Scanning inaccuracy use of dump key inherent error rate missed product staff training, discipline, holiday / sickness Booked-in against wrong suppier identifies regional/format wrong title(covariants wrapped supplement) Unrecognised product on file SUPPLY ISSUES LIVE PRODUCT poor stock control system singles/small at W/S preprocess Theft from made up returns parcel at back door from stockroom difficulty in checking supplies from stockroom not left out In store process home delivery/ shop saves Special accounts Claim for short supply not made/made late LIVE SUPPLY ISSUES firm sale publisher product status change operator error completion errors staff awareness Returns note Damage not received by stockroom not actioned by stockroom Opt not to return holiday returns note completed by more than one person or at different times Fraudulent claim covermount missing from partwork Validation rejects credit partworks manuall count Returns notes incorrectly completed weekend sickness poor staff awareness poor title/issue I.D Lack of audit poorly secured internal transfer from another store sub retail account booked out forecourt wrong a/c home delivery/ account shop save too late Staff not customer promotional return misplaced on point product / display poor initial return late shelf fill/ staff dump replenishment Multi-locations product fall behind display stockroom Vouchers not sent back properly RETURNS ISSUES OFF-SALE PRODUCT Returns not booked out sent back not dispached lost in wrong W/S properly store, back door stores not 1st f/s issue return known partwork crowded late/f/s product discounting/ display procedures give away to off site/remote and awareness clear stockroom Staff coverage miscounted to wrong W/S dual W/S staff supply awareness process too many returned system error poorly attached Lack of audit muliti supplier W/S not supply time window too tight W/S Not collected Theft Staff coverage unidentified parcel keyed after cut off Mis-scan Stickers over/under No cover mount poor handling/ packaging at back door in full or part W/S not recall title left wrong place Non standard shape/size Cover damage - no bar code Collusion varying time windows local weeklies wholesale too set-up as slow to scan dailies for too late query recall resolution Bundles lost in transit loose product poorly packaged Bundle unidentified at no label scan in transit between driver/ another outlet procedures Frequency of collection affects W/S process time makes returning difficult Not booked-in/ checked W/S lack of documentation informed continuity staff awareness Damage not read Stickers Display/ handling problems lack of audit new title/one shot affects 'at risk' time in shop Full bundle short(assumed quantity at retail-individual copy scan at W/S Bar code incorrect info. from publisher retail poorly label Product characteristics Systems/ Information publisher bundle mispack over/under SHRINK - CAUSE & EFFECT RETURNS ISSUES (OFF ) Systems/ Information Wholesaler returns process poorly labelled confusion over related box (forecourt, shop save) price SHRINK - CAUSE & EFFECT SUPPLY ISSUES (LIVE PRODUCT) staff canteen from wrong account In store process RETURNS ISSUES Prioritising Hot Spots & Quick Wins Severity x Probability = Focus Factor Score 5 4 3 2 1 Severity of Failure (S) Major Loss Impact Some Loss Impact Individual Item Loss Possible / Uncertain Loss Little Impact Probability of Occurance (P) Daily / Inevitable Weekly / Repetitive Every few weeks / Occasional Every few months / Rare Rare & Irregular Focus x Addressability = Quick Win Factor Score 5 4 3 2 1 Time / Effort to Address (A) Can do easiliy & cheaply / Weeks Needs some effort but little cost / Quarter Minor systems & protocol effort Requires development over months Major systems & Commercial issues Objective Priorities Hot Spots Quick Wins Industry From Analysis to Actions Objective build up as a team .. Scoring .. Reviewing .. Etc Mutual, logical view .. As part of Big Picture Leads To 4 Key Action Areas Credit Claims Period Product Identification Key Areas In-store processes Small steering group Manage specific work parcels Firm, objective co-ordination Supply Management Rigorous & robust Key Achievements to Date Credit Claims: New ‘synchronised’ period Benefit ~ €3m p.a. to Retail from July 2003 .. -23% Audited … Hard wired … Sustainable Step Change Product Identification: Error Reporting Measure .. report .. inform .. educate Web based ‘National Title File’ www.nationaltitlefile.co.uk Publisher Notification Form Date Publisher Title on Calendar Title apparent on magazine Issue On Sale Recall Price Barcode 04-Mar-04 Seymour Disney & Me special Finding Nemo Finding Nemo 27-Feb-04 09-Apr-04 £1.99 977146959500002 Key Achievements To Date Supply Management: Sales Based Replenishment Modelling & pilots .. lead to Best Practice Guide Menzies Test .. 6 depots, 218 customers, 100 titles Benefit .. Sales +2.6 %, Returns -51% In Store Process: Best Practice Simple guide produced to benefit all retailers “3 Areas where Shrink eats away your profits” “If you do nothing else .. Do This” “Golden Copies!” ECR .. Leads to Joint Sainsbury’s-Menzies Action Sainsbury's & Menzies Shared common Roadmap approach Address holistically .. Big Picture .. Not Knee Jerks Resource jointly .. Sainsburys team + Shrink Doctor Leverage from Industry work A clear joint Brief Aim for understanding and sustainable actions Target ‘Hot’ stores Map .. Benchmark .. Quick Wins Sainsbury’s Issue Identification Mapping, Analysis & Risk Assessment points to Key Issues Procedure & Training Processes Management Information Poor Data Management Returns Process Theft \ Security Colleague Issues Stock Holding Stocktake Dual Supply Actions & Achievements Procedure & Training Introduced a supplier funded Colleague handbook Built Wholesale relationship & Raised our Internal profile Process ‘Invoice Matching’ .. More robust store charging system Simple & more robust stocktaking process Information Produce timely Management information throughout estate Wholesale data feed of “rejected” returns Shrinkage down 25% .. Sales up 10% .. At Pilot stores Key Learnings Sainsbury’s-Menzies Collaboration Got stuck in .. Dug out the facts .. Learned from the front line Whole new meaning to the word “observe” .. Objective appraisal Did it for real bottom up, In detail .. Identified the basics Knee Jerks – Only deliver short term results Sustainability .. Comes from End to End process understanding Retailers / Wholesalers encouraged to do more There are NO short cuts! Key Learnings Industry Collaboration Industry-wide Collaboration can be done .. But it’s a Journey! Requires clear systematic focus .. And the right people Blue Book .. supported move from Subjectivity to Objectivity You CAN move from ‘Them & Us’ to … ‘US!’ Technical analysis .. & .. ‘People’ issues Its about Solving! .. Not shifting! Within the Big Picture .. for Sustainability The journey continues .. We are still walking & talking together In Conclusion Measuring Stock Loss: Developing a KPI Dr Paul Chapman Cranfield School of Management Issues to Consider • • • • • A clear definition of “Stock Loss” The scope of the issue Method of calculation Methods of valuation Focused management action A Clear Definition of “Stock Loss”? • Internal theft + external theft + process failure (including waste) + inter-company fraud • All inputs that cannot be accounted for The Scope of the Issue • Holistic, supply chain view: – raw material to shopper, e.g. the cow to the fridge, including returns • Being practical: – Limit the start of the supply chain to either: • Declared production in the factory • Product in manufacturer’s DC – Limit end point in the supply chain to either: • The shelf • The checkout Method of Calculation • Total Stock loss = Known loss + unknown loss – Discrepancy between book stock and physical stock – Net inventory + net movements – (opening stock – closing stock) + ((purchases + incoming transfers) – (sales + outgoing transfers)) • Where known loss: = Known theft processed + Known errors processed (including: write offs; damage; donations; mark downs; cost of sales adjustments; out-of-date; tasting) ow at by 3P Ls t s po r ns C s es RD oc Pr tio ns e ns at e am ag D on a Tr a es in Lo ss es Lo ss es O th er D D ed M ar k of D n 100 Lo ss e ic Pr ow ow n Kn nk n O ut U Percent Categories Included Store issues Supply chain 75 50 25 0 Methods of Valuation • Loss as a percentage of sales Total stock loss Sales X 100% • Value of loss calculated at either: – Sales value • Gross including VAT • Net excluding VAT – Purchase price – Transfer price Method Used 45 40 Per cent 35 30 25 20 15 10 5 0 Retail Sales Value Cost Price Cost Price + Other To Conclude: Deliver Focussed Action • Use your data – Top level KPI reveals total opportunity – Cascade measure to expose under performance • Know how to take action – The ECR Roadmap • Dedicate the capacity to implement • Drive progress against targets Makro & Gillette: on track with the ECR Shrinkage Roadmap Werner Cooreman, Makro Dieter Mertens, Gillette Programme • • • • • • Profiles Collaborative objectives Phase 1: defensive Phase 2: innovative Phase 3: the ECR shrinkage roadmap Take away Profiles: the retailer - the supplier > 1,2 billion € > 70.000 SKU > 3.600 employees > 1 million customers Collaborative objectives Evolution of Objectives through phases of improving collaboration Less Shrink Less Shrink + more sales better performance mid 2002 mid 2003 2004 Phase 1: defensive • PHASE 1: – Makro Call – Shoplifting – Safercases Results Shrink: - 80% (approx.) Phase 2: Innovative • PHASE 2: – Gillette Call – Shoplifting + Back office – Clamshell C&C pack Results Shrink: stable at 0.2% Sales: + 131% (pilot test) Phase 3:Using the Roadmap • PHASE 3: – Full Collaboration – Holistic approach – Store supply chain solution Results Shrink: - 20% (Q1); ongoing... Sales : + 18% (Q1); ongoing... Phase 3:Using the Roadmap 0. Wake Up 1. Plan 6. Evaluate 2. Map & Measure 5. Implement 3. Analyse 4. Develop Solutions Illustration Road Map by video Phase 3:Using the Roadmap Plan SHRINKAGE - 10 % October 2003 SALES Mach3 family + 20% October 2004 Map & Measure -2000,00 Focus on Mach3 Family (12 pack & 4 pack) -1500,00 -1000,00 -500,00 1 0,00 GI LLE T T E CONT OUR P LUS 10 M E SJE S GI LLE T T E GI I 10 M E SJE S GI LLE T T E GI I P LUS 10 M E SJE S GI LLE T T E M A CH 3 12M E SJE S GI LLE T T E M A CH 3 4M E SJE S GI LLE T T E M A CH 3 A P P A RA A T GI LLE T T E M A CH 3 A P P A RA A T COOLB LUE GI LLE T T E SE NSOR 10 M E SJE S GI LLE T T E SE NSOR E X CE L A P P A RA A T GI LLE T T E SUP . SI LV E R 10 M E SJE S Analysis Process Map MAKRO - GILLETTE PILOT FMEA FOOD DEURNE 1. Camion komt toe aan de V PROCES FLOW CHART 1. ONTVANGST 2. Chauffeur biedt pakbon in 2 ex aan loket aan 3. Ordercontrole in BORISdoor bediende 4. Levering krijgt GO nummer Exemplaar met sticker voor leverancier gaat in bakje Process Map 5. Chauffeur krijgt pakbon met sticker voor 'Makro' terug 6. Chauffeur ontlaadt pallet (geen zegel) 7. Chauffeur biedt pallet aan bij ontvanger Indien levering klopt, worden de doc gewisseld door ontvanger 8. Ontvanger voert 1e Controle uit 9. Chauffeur voert door naar transitruimte NAAR 2e CONTROLE 8A. Controleert het document 8B.Telt het aantal eenheden/colli vermeld op bon 8C.Vergelijkt dit aantal met paklijst Root causes analysis Failure Mode & Effect Analysis Possible Solutions Gillette 10 step process Implementation 1.secure storage 4.check delivery 3.fast tracking to secure area 5.visible location Implementation 6.Anti-theft fixtures 8.regular counting 7.frequent replenishment 9.staff awareness Evaluation • Overall preliminary results: Shrink (3 phases): - 85% Sales (3 phases): + 18% • Positive acceptance on the workfloor • Roll out solutions (10 Steps) in other stores • Final evaluation due October 2004 Take away • Use of the roadmap requires commitment • Loss prevention is about simple issues: stock control, identifying opportunities,…but with great impact • Collaboration works Thank you for your attention ! Wrap up John Fonteijn Royal Ahold Co-chair, Shrinkage Working Group An Invitation ... • Join our working group • Use the Road Map • Share your results ECR Shrinkage Award • To the person / organisation that has made the most significant contribution to shrinkage reduction in 2004 – 5. • Judging criteria: – Approach – Results – Dissemination – Sustainability Thank you Q&A