@ Supply Chain Management

I couldn’t resist the pun. Long time readers of the blog would know very well that the insights of Taiichi Ohno hold a special place in my corpus of intelligent and wise things to have around. So it is a rather “Deming – like” sort of conundrum to have at hand an Oh No!! moment from Japan itself : Bernanke just felt a chill down his spine.

If you are not plugged in into the vast array of paralyzing news that flows around you or perchance missed this rather telling problem that has arisen in Japan of late.

In April 2013, Japan announced a QE program of $1.4 trillion, an amount equal to roughly 25% of the Japanese GDP. To put this into perspective, the US’s QE1, QE 2, QE 3, and QE 4 programs which were spaced out over four years are an amount equal to roughly 16% of US GDP.

When people refer to QE (Quantitative Easing) by the central bank, they almost always refer to it as if it were the only driving factor in the land. You have to remember that both Japan and the US has been running budgetary deficits as well. For Japan, it looks like this : Japan Government Budget (as % of GDP).

For the US, it looks like this : US Government Budget (as a % of GDP)

But,

Japan announced a larger program relative to its economy all at once. The idea was that by throwing around a big enough amount of money, Japan’s economy would finally waken from its 20-year slumber and take off.

This effort has been an abysmal failure. Japan’s second quarter GDP grew at just 0.6% quarter over quarter, registering the single biggest growth MISS in a year (economists were expecting 0.9% which, by the way had already been revised lower).

Put in plain terms, Japan announced the single largest QE effort in history, and not only did its economic growth projections have to be lowered, but it is failing to even meet these lowered growth projections.

So, the noted result is that the GDP came in lower than the lowered forecast. For now. Oh no!!!

So what is supposed to happen?

The central bank – BOJ, Bank of Japan, being one of the bigger behemoths (financially speaking) in a country, can wish into existence more money which they then use to buy bonds. Why bonds and particularly govt. issued bonds? The point is that that’s where a lot of people have parked their monies because of the current state of the economy – accepting a nominal return in exchange for safety. By buying bonds with seemingly inexhaustible (though the only currency that is truly inexhaustible is stupidity but even a simple familiarity with the human being shows that they do get tired from time to time) i.e. magically created monies, the BOJ hopes to drive down the yield on the said bonds such that if people holding bonds currently felt that they were getting a whole lot of safety, they were going to get even less return for that safety. Ergo, those monies would be then retrieved and ploughed back into comparatively riskier assets such as stocks (i.e. the preferred funding mechanism for new ventures) which then leads to hiring instead of firing and so on.

Except that the GDP measure that is supposed to show the increase in “virtuous” activity that all this QE was supposed to engender has not worked out as well as one would have expected.

And so what is one to make of this?

Perhaps this Oh-No!! moment can lead us to what I appreciate as the central Ohno (the Taiichi kind) precept i.e. Respect for People. You see, when the BOJ (and as an agent for action, one cannot deal with a more ill-suited agent. In a firm, the BOJ would be the payroll + performance manager combined) wades onto the scene, the fundamental action is to whip people around, to coerce them into an action. You see the problem?

Let’s get something straight here – while stupidity is a truly inexhaustible resource in this world, between the ears of each and every human being is an explosive and creative engine. Unleashing this engine can only be contemplated as an extension of the inherent respect that every man, woman and child are inherently owed as their endowment.

All the machinations of central planners and allied commentators take the track of either, “Messing with/exciting the animal spirits”, or “Devaluing the efforts of people in the past i.e. through inflation” or the like.

As these Oh-No’s pile up, perhaps, it would be a wise thing to see how Ohno studied the matter in a factory on a small island far away…

This is an interview with Pierre Haren, CEO of ILOG prior to its acquisition by IBM on what decision management is and how it came to be used in various situations. A look back (and forward) at 20 years of Decision Management.

This is also my particular field of expertise and Pierre alludes to the case of the product that I work with gaining acceptance in IBM’s wafer fabrication facility in East Fishkill, NY.

We had a great moment when we were able to successfully deploy a complex mix of ILOG and IBM tools at IBM Fishkill, in what was considered the most modern and fastest changing semi-conductor plant in the world. At that time, before our acquisition by IBM, IBM was a reluctant customer. I visited the head of the plant and promised that we would install the complete system for free. He would only pay if he kept the system in operation for more than a month.

Understandably, he was skeptical that a small decision management company could improve on the work of hundreds of excellent engineers who continuously tuned the $4B plant. We deployed a system which every five minutes re-computes the optimal plan for the whole plant for the next eight hours. It combines real-time data from the MES system to rules-based processes, an optimization-based scheduler, and advanced graphics to enable the plant operators to "see the current future" for the next eight hours.

The first day’s objective was low: do no harm. Within a month, all the operators where convinced and we were paid. More important, we changed forever the balance of what computers do and what operators do in that plant.

What’s important about this confluence of components i.e. Rules Management, Optimization using CPLEX and Visualization as it used in that fab (and since then in other fabs in the world) is how such a system can be used for execution. Not planning, Not strategy. But execution on a near real time basis – that means that actual tools on the fab floor act on the recommendations produced by the decision management system which in turn sees the action of the tools and then uses that as an input in further decisions. When operators and managers assert manual control in the operation of the tools or fab in general, the system accepts that and continues without issue. So the system takes into account the dynamic nature of the fab, recomputes and proceeds. I’ve blogged about this system : FabPowerOps in earlier blog postings – take a look.

Now I’m hoping to take this to the next level, deploying a federated system of such applications that not only interact with the fab floor as well as human operators, engineers and managers but with other apps taking their inputs and working on that.

Great stuff, I assure you!!

Two recent articles, one being the retelling of another, delve into some of the reasons why Apple makes iPhones in China and by implication not in the USA. The original article was from the New York Times, How the US lost out on iPhone Work and the retelling was recounted in This Article Explains why Apple makes iPhones in China and why the US is screwed.

There is no article about China which doesn’t recount some of the following snippets:

When one reads about these working conditions — 12-16 hour shifts, pay of ~$1 per hour or less, dormitories with 15 beds in 12×12 rooms

For Mr. Cook, the focus on Asia “came down to two things,” said one former high-ranking Apple executive. Factories in Asia “can scale up and down faster” and “Asian supply chains have surpassed what’s in the U.S.”

“The entire supply chain is in China now,” said another former high-ranking Apple executive. “You need a thousand rubber gaskets? That’s the factory next door. You need a million screws? That factory is a block away. You need that screw made a little bit different? It will take three hours.”

“The entire supply chain is in China now,” said another former high-ranking Apple executive. “You need a thousand rubber gaskets? That’s the factory next door. You need a million screws? That factory is a block away. You need that screw made a little bit different? It will take three hours.”

That’s because nothing like Foxconn City exists in the United States.

The facility has 230,000 employees, many working six days a week, often spending up to 12 hours a day at the plant. Over a quarter of Foxconn’s work force lives in company barracks and many workers earn less than $17 a day.

And lastly,

The answers, almost every time, were found outside the United States. Though components differ between versions, all iPhones contain hundreds of parts, an estimated 90 percent of which are manufactured abroad. Advanced semiconductors have come from Germany and Taiwan, memory from Korea and Japan, display panels and circuitry from Korea and Taiwan, chipsets from Europe and rare metals from Africa and Asia. And all of it is put together in China.

Summarizing, Chinese firms can scale up and down rapidly i.e. they have flexibility that the Chinese government and populace are willing to allow. Something that cannot be obtained stateside in whatever shape or form. The key takeaway is that it is not only scale but the willingness and ability to go either way with it. In the US, one finds that scale is directed one way towards growth but scaling down is an arduous, acrimonious and drawn out affair if it ever happens.

So here’s the first key to Smarter Manufacturing – Flexibility and Scalability.

I want to highlight a “cool” scholarship made available by D.W. Morgan for college students – “Last Mile” Scholarship. I urge you to pass it on to individuals who may (and better yet, may not at this time) be considering a career in Supply Chain Management and/or Transportation Management. Talent is always going to be the differentiator when it comes to the Supply Chain Edge and such scholarships and experiences go a long way in creating those edges.

From the scholarship write up:

The D.W. Morgan “Last Mile” Scholarship
Imagine you’re a senior in college.  An ambitious, successful college senior, ready to take on the real world.  You graduate, move back in with your parents, and begin your job search.  Wouldn’t $5,000 be helpful?  $5,000 and your dream internship to help you get started?  I wish I had had that chance when I was there.
DW Morgan is making exactly that possible for 4 talented seniors by sponsoring a scholarship for students interested in supply chain, logistics and transportation management.
The task is simple: come up with a way to revolutionize the industry while making a positive global impact.  Easy, right?  Ha.  It’s called the “Last Mile” Scholarship, and the four winners are picked to receive $5,000 each, and the grand-prize winner out of those four gets the opportunity to intern at a DW Morgan location in the summer of 2011.
Interested?  Check out the website: www.lastmilescholarship.com for official rules, qualifications, submission guidelines and other information

In my earlier post, I had said that I was working on the idea/concept of a Living Wage. Some eyebrows might have popped at this – if not, this would be a good time to go a popping. After all, what is the connection between a Living Wage and the supply chain?

Take a look at this report for instance: Why is Wal-Mart blocking 35 cents an hour for Bangladeshi workers?

From that article,

Senior sewers are paid 1.7 cents for each pair of Wal-Mart jeans they sew. (Each worker must sew 10 pairs of jeans per hour, or one pair every six minutes—which is 10 percent of an hour. Ten percent of their 17-cent-an-hour wage amounts to 1.7 cents.)

That’s an hourly wage of US$ 0.17 for experienced sewers and the current demand is to raise the wage to US$0.35 (and up to US$ 0.51 by some accounts that I have researched).

The obvious question is : Is an hourly wage of US$0.17 a living wage? Is an hourly wage of US$0.35 or US$0.51 a living wage? If you think that US$0.17 is an absurdly small number, what do you make of US$0.35 or US$0.51? If you’re mortified by the idea that the designer jeans that you’re donning tonight was sewn together in misery, will you be gratified by the notion that they will be paid double that wage if you just bully the capitalist/retailer to forgo that marginal hit to his profits?

Now coming back to stateside, take a look at this site from Penn State that enables you to work out what constitutes a living wage in America, by state, by county – Living Wage Calculator. I live in Newburgh, NY and so I took a look at what constituted a living Wage for Newburgh, NY – A  living wage for Newburgh, NY.

A family with two adults and two children require a wage of $60,274 in order to “live” in Newburgh, NY which works out to a $28.98 hourly wage while the Minimum wage is $7.25 and Poverty Wage is $9.83.  Of course, this calculation does not include any governmental assistance which spans the spectrum of wages from ~ $20,000 to ~ $60,000 depending on family configuration.

The critical issue with the living wage is that is has nothing to do with living or working – it has to do with calculations in Ivory towers. There is no such thing as a living wage (just as there is no such thing as a minimum wage) – the effort to create a living wage is about replacing the antiquated notion of a minimum wage by something more substantial. What the residents and denizens of Ivory Towers and various social justice movements don’t understand is that a Living wage like the Minimum wage before it is a calculation that looks good on paper and might even absolve the bean counters and theoreticians from enjoying their privileged lives. It will do nothing to lift those Bangladeshi garment workers out of poverty and neither will it change the lives of those living stateside.

All that it will accomplish is that the annual wage of CEOs in the millions will then become in the billions, the annual wage of the consultant in the hundred thousands will be in the millions and so on. The poor will still be poor and probably poorer still because for the decade or so (and it will be much faster than that) that it would take to adjust, they will have adopted habits and lifestyles that will leave them worse off.

If you don’t believe what I say, take the hypothetical Bangladeshi worker who, through all the unrest in Bangladesh, doubles (from 17 cents to 35 cents an hour) or triples (from 17 cents to 51 cents an hour) his/her hourly wage. When that dramatic increase in wage happens, what I’d like you to do is tell me what happens to his/her life?

1. Wage – we know this already because it is a given, doubled or tripled.

2. Rent Cost – ?

3. Transportation Cost – ?

4. Food cost – ?

5. Medical cost –?

6. Taxes – ?

7. Entertainment costs – ?

8. Other costs – ?

Do you think items, 2 through 7, increase, decrease or remains the same?

I think that such misguided thinking betrays a mistaken notion of the concept of profit. I think that the most fundamental error that the calculators always make is to think that all that needs to be done is to carve out a portion of profit and return it to labor. And what always happens is that the profit margin remains unchanged or is impacted ever so slightly and everything else is adjusted accordingly.

Profit is notoriously difficult for the Ivory Tower to understand. And the reason is quite easy as well – they’ve never really worked in the real world. For some Profit is a subtraction of numbers and for others it is the recompense for overcoming fear – these two worlds will never meet.

A living wage is a confident calculation about the static nature of human enterprise and economy. And that calculation is wrong. Profit is a dynamic calculation of the nature of human enterprise and economy.

My introduction to the stateside supply chain of the US government was through the Dept. of Defense of which the DLA (Defense Logistics Agency) is a principal player. So the news that Accenture won a four-year $73 million contract is news that rings close to me.

Accenture has won a four-year, $73 million contract from the U.S. Defense Logistics Agency to integrate its energy supply chain with its enterprise business system program, the consulting company said Tuesday.

And the scale of the DLA’s activities,

When the project is finished, the Defense Logistics Agency will have added more than $18 billion in traceable items to its supply chain, Accenture said. The agency averages 54,000 orders and 8,000 contracts per day and manages 520,000 shipments annually.