Toyota Production System (Bussiness Case Studies & Plan)
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Transcript of Toyota Production System (Bussiness Case Studies & Plan)
Topic Outline
Introducing Toyota Australia&
Her Supply Chain Management
By Cong Xue
History of Toyota Australia
• Toyota Motor Corporation Australia (TMCA) is a subsidiary of Toyota Motor Corporation (TMC).
• Toyota Australia’s origins go back to 1958.• The commercial vehicle business became
Thesis Toyota in 1971• In 1988, Toyota’s local operations were unified
to form Toyota Motor Corporation Australia• Toyota Australia currently build two models—the
Camry and Avalon series.
Toyota Australia Current Business
• Toyota Australia is the second largest vehicle manufacturer in Australia.
• Toyota Australia has exported over 60,000 cars to over 20 different commercial locations worldwide in 2003.
• Toyota is a people oriented organization that sees the development of its staff as a foundation stone for future business prosperity.
• Toyota has long been recognized as one of the most efficient manufacturers in the world
Business Context
The business context of Toyota Australia is actually link tothe operating environment that consists of a number offactors.
– The global industry operating environment; – Automotive investment trends; – Policy environment; – International market access; – Australian industry operating environment; and – Government policy environment.
Toyota Australia’s supply network
The basic of Toyota Australia’s supply network:
– Supplier Association– Effect of “knowledge sharing network” on
supply chain coordination– Upstream and downstream entities
Suppliers Association
• The key to Toyota’s success would appear to be their highly effective supplier integration process that over the past 50 years has enabled the excellence of their internal “hoshin kanri” strategic management, cross functional process based management and Toyota Production System to be shared directly with their direct suppliers.
Effect of “knowledge sharing network”
• The effects of knowledge sharing network on the coordination of supply chain and product customization forms the basis of Toyota Production System (TPS).
• The aim is to have members identify themselves as part of an interdependent economic network.
The Upstream problems
After a series of research, few critical factors were identified:
– Bundled outsourcing– Logistic challenge – Import of vehicle components
Bundled Outsourcing
• One of the important characteristics of Toyota Japan suppliers system in terms of the inter-firm tasking portioning is that the outsourcing ratio is high not only in manufacturing but also in product development.
• There is a difference in terms assembly process and the level of hierarchy in supplier.
• Without bundled Outsourcing, it has first changed the internal process of the supply chain and most importantly, the number of first tier suppliers decreases and many of the suppliers ascended to the higher tiers and the hierarchy of the parts markers.
Logistic Challenge
• One advantage of localization is closer relationships facilitate collaborative problem solving.
• Longer supply lines required faster order processing, and this was done electronically.
• Essentially, electronic kanban cards were identical in function to the physical kanban cards used by Toyota in Japan.
Import of Vehicle Components
• In the case of Toyota Australia, only 79 per cent of components are local content, with the balance relying on imports.
• This has been highlighted as one of the critical factors in terms of supply chain due to the fact the it affects the supply chain coordination as well as the upstream entities.
Upstream Entities
At current, Toyota Australia has an extensive local supplier base from its 98 component suppliers and 300 general suppliers.
In general, suppliers may be broadly classified into three categories:
– Parts suppliers (Key component/ low assets specificity component)
– Raw materials suppliers – Suppliers of equipment and tools
Downstream Entities
In general, Toyota Australia has the following downstream entities:
– Warehouse facilities in all major states – Distributors in all major states – Dealer network of over 285 outlets across
Australia
Internal entities To build a car, the internal entities of the supply
chain which includes all of the in-house processes used in transforming the inputs from the suppliers are as follows:
– Production of Engines (Once completed, the engines head straight for the final assembly)
– Pressing of steel panels and parts – Welding of car shells – Painting of car shells – Final Assembly
Topic Outline
Toyota’s Australia &
Her Current IT Setup
By Simon Chew
Topic Outline
IT Solution for Toyota Motor Corporation
(TMC)
IT Solution for TMC
• Enterprise Resource Planning System (ERP)
• E-Marketplace
• TradeMatrix system
IT Solution for TMC
Enterprise Resource Planning System (ERP)
Enterprise Resource Planning System
Why ERP?
Enterprise Resource Planning System
• One of the largest automotive companies in the world
• Total of 51 overseas manufacturing companies in 26 countries / locations
• Overseas network consisting of more than 160 importers / distributors and numerous dealers.
Enterprise Resource Planning System
• SAP Automotive ERP Suit • Main means of information flow between
Toyota and its counterparts worldwide.• Tighter collaboration links • With SAP, gain:
– Outstanding strategic,– Operational,– Financial,– Marketing positions
IT Solution for TMC
E-Marketplace
TMC E-Marketplace
• iStarXchange • Initiative with i2 Technologies Inc.• Allow subscripted members able to view a single
catalogue to:– view information on parts – checking the prices and availability– conduct transaction online– forecasting supply and demand – delivery cycle
• Improved forecasting • Enhancing the planning• Enhance deployment and replenishment of the inventory
IT Solution for TMC
TradeMatrix system
TradeMatrix system
• Initiative with i2 Technologies Inc • Automates with equipment manufacturer
and suppliers in terms of : – site’s inventory management – warehousing – Logistic and shipping
Topic Outline
IT Solution for Toyota Motor Corporation
Australia (TMCA)
IT Solution for TMCA
• Main SAP Automotive suit ERP system• BEA Web-logic Integration 8.1 (Integrated
within the SAP automotive suit)• Electronic “Kanban”-Card System• Participant of iStarXchange • Major Player in Australian Automotive
Network eXchange (AANX)
IT Solution for TMCA
Main SAP Automotive Suit ERP System
Main SAP Automotive Suit (ERP)
• Main means of information flow between Toyota Australia and its counterparts worldwide.
• Tighter collaboration links between TMCA and TMC– Logistic and shipping– Overall Value Chain
IT Solution for TMCA
BEA Web-logic Integration 8.1
BEA Web-logic Integration 8.1
• Integrated within the SAP automotive suit• Main IT Backbone of TMCA• Based on Open Standard• Allow connection to their numerous
partners in the value chain via an assortment of systems in Australia
• Integrate the systems and processes that connects Toyota Australia and its trading partners
BEA Web-logic Integration 8.1
• Functions:– Electronic proof of delivery – Online accounts payable status for suppliers– Fleet management integration– The Toyota Vehicle Order Processing
System (TVOPS)– Advance Shipping Notice for vehicle
deliveries– Vehicles inventory synchronization
BEA Web-logic Integration 8.1
Customised BEA Application
BEA Web-logic Integration 8.1Financial management functions
IT Solution for TMCA
SAP vs BEA
SAP vs BEA
1st Tier/ 2nd Tier
Suppliers
End Customer
Dealers
Warehouse/ Parts Centers
Manufacturing Plants
International collaboration
Raw Material Suppliers
SAP/BEA
IT Solution for TMCA
Electronic “Kanban”-Card System
Electronic “Kanban”-Card System
• Identical in function to the physical “kanban” cards used by Toyota in Japan
• 4 main purpose:– Sole means of requesting new parts – Send for every order shipment – Send to a specific supplier plant – Establishing the mix and volume criteria for
assessing if an order was correct
Electronic “Kanban”-Card System
“Kanban”= Card (Japanese)
Electronic “Kanban”-Card System
SYSTEM
PARTSSUPPLIER
TOYOTA(TMCA)
PlanningPlanning
Despatching
AccountsReceivable
AccountsPayable
Receiving
Material Requirements Forcast
Remittance Advice
BANKING
OrdersForecasts
ProductionLine
Kanban Sorting
Delivery Docket
Delivery Docket
Goods
Kanbans
Kanbans
ANSI X12 830
EDIFACT REMADV
EFTEFT
IT Solution for TMCA
Participant of iStarXchange
Participant of iStarXchange
• Main e-marketplace between TMCA and its counterparts worldwide
• Allow subscripted members able to view a single catalogue to:– view information on parts – checking the prices and availability– conduct transaction online– forecasting supply and demand – delivery cycle
• Improved forecasting outside Australia• Enhancing the planning outside Australia• Enhance deployment and replenishment of the inventory
IT Solution for TMCA
Australian Automotive Network eXchange (AANX)
Australian Automotive Network eXchange
• Four major car manufacturers in Australia are involved
• Numerous service providers and non-key suppliers
• Provides IP based Extranets for the automotive industry in Australia
• Operates as a virtual point network (VPN)• Allows users to send date to each other in
a reliable and secure manner
Australian Automotive Network eXchange
• Main components:
– A network that is based on available Internet technology
– Operated by agreed and standardized service levels.– Demonstrating proactive management of trading
partner connections– Practice the best standard of security and privacy for
transactions and interoperability between service providers
Australian Automotive Network eXchange
• Benefits includes:– Pervasive supply chain communications– Rapid application deployment across the
supply chain– Lower cost of EDI– Faster Business Cycles– Simpler integration into trading partners' and
customers' online e-business systems and strategies
Australian Automotive Network eXchange
TradingPartner
TradingPartner
AANXO Monitor
CASP Keytrust
Community Directory &
Authentication
FirewallHardware Gateway
Router
Permanent Connection
Firewall Hardware Gateway
Router
Permanent Connection
Dialup trading Partner
IBM Compatible
Laptop Computer
Modem
Modem
Software Gateway
ConnectEquant
Exchange Point
AANX Framework
IT Solution for TMCA
Problem Statement
IT Solution for TMCA
Weaknesses • Lack of alternatives in the domestic supplier
base and risk of currency exposure• Problems arising in linear supply chain• Over-reliance on forecast planning for
production• Lack of Vertical industrial relations environment
IT Solution for TMCA
Lack of alternatives in the domestic supplier base and risk of currency
exposure
IT Solution for TMCA
• TMCA’s supplier agreements have to be obtained with the approval of the TMC
• Import costs and extended time taken for components to arrive in Australia hinder TMCA’s JIT system.
• Currency exposure will cause too great a financial risk for TMCA
• Components also take longer to arrive the plant • Affect on the overall production costs and time taken to
produce a “locally produced” Toyota cars
Lack of alternatives in the domestic supplier base and risk of currency exposure
IT Solution for TMCA
Problems arising in linear supply chain
IT Solution for TMCA
• Dispersed geographical location of the TMCA supply chain infrastructure
• Cannot currently communicate and interact with other members further downstream
• No collaborate in spite of TMCA’s involvement with the AANX network
• Escalate problems with ongoing redundant supplier delivery expenses
Problems arising in linear supply chain
IT Solution for TMCA
Over-reliance on forecast planning for production
IT Solution for TMCA
Over-reliance on forecast planning for production
SYSTEM
PARTSSUPPLIER
TOYOTA(TMCA)
PlanningPlanning
Despatching
AccountsReceivable
AccountsPayable
Receiving
Material Requirements Forcast
Remittance Advice
BANKING
OrdersForecasts
ProductionLine
Kanban Sorting
Delivery Docket
Delivery Docket
Goods
Kanbans
Kanbans
ANSI X12 830
EDIFACT REMADV
EFTEFT
IT Solution for TMCA
Lack of Vertical industrial relations environment
IT Solution for TMCA
• Currently industrial relationships with automotive manufacturers in terms of sharing suppliers
• Current AANX network relying on the freight company to do all the logistics planning
• Automotive shipments require specialised vehicle transport ships
Lack of Vertical industrial relations environment
IT Solution for TMCA
Business Goals
IT Solution for TMCA
Business Goals1. Provide a comprehensive domestic
supplier base 2. Provide initiatives for a non-linear, hub-
based supply chain system 3. Provide real-time updates on demand
and supply allocation 4. Vertical industry logistics collaboration
IT Solution for TMCA
Solutions Overview
IT Solution for TMCA
Goal 1: Provide a comprehensive domestic supplier baseSolution: Implementation of a supplier website
Goal 2: Provide initiatives for a non-linear, hub-based supply chain system Solution: An agent-based e-marketplace initiative.
Goal 3: Provide real-time updates on demand and supply allocationSolution: Real-time tracking function module incorporated into the current
electronic BEA system
Goal 4: Vertical industry logistics collaborationSolution: An intelligent logistic coordinating agent in the form of a
collaborative e-logistics hub.
Solution 1
Solution 1Implementation of a supplier website
By Joseph Baez
Solution Description
• Goal 1 – Provide a Comprehensive Domestic Supplier Base
SOLUTION: Implementation of a supplier web site– U.S. version of Toyota supplier web site
• Toyota Supplier.comwww.toyotasupplier.com
Supplier Website
Supplier Website• TMCA focused on core competencies in
– high-end design– engineering and– system integration
• Toyota Australia needs highly focusedcore competency oriented suppliers.
• Small and diverse companies though have the ability to display such potential to add– Innovation– Flexibility and– Strength to TMCA’s supply base.
• TMCA first has to open its doors to the domestic market suppliers– Invest in their new concept of supply base
• Target: 100% domestic suppliers
• Supplier-centric web site– Provide – opportunities
to expand TMCAsupplier network.
Supplier Website
Supplier Website
Figure 6. Access Flow From ToyotaAustralia Suppliers web site
Reasoning behind Goal 1 – The Business Needs
• Many of TMCA’s car components have to be imported due to the lack of domestic suppliers
– Application of the “right part at the right place at the right time” concept or JIT to lack the optimal efficiency throughout the TMCA supply chain.
• The implementation of a comprehensive domestic supplier base is essential.
• Provision of collaborative web site linking current TMCA online presence which provides similar functions to the Toyota supplier’s web site currently in use in North America
– Allowing TMCA to have comprehensive overview of their current suppliers.– Also reducing the red-tape involved to be part of the TMCA supply chain; and
most importantly– Provides TMCA with a channel to disseminate important supplier related
information to its upstream entities.
Supplier Website
• Web site functions– Potential suppliers will be able to acquire information on the requirements of
becoming part of TMCA’s supplier network• Potential suppliers need only to download/complete an online form
to join the network• Information such as
– Supplier’s guide– Community activities; and– Any core information about TMCA’s current supplier’s network can be obtained from the
website.
– Connection links provided to domestic e-Marketplace• Registered e-Marketplace members:
– Able to enjoy the privileges on what the e-Marketplace is offering• To be discussed in Solution 2
• New opportunities for potential suppliers as well as existing suppliers who possess the capabilities to improve TMCA’soverall supply chain process using this proposedcollaborative web site.
Supplier Website
Solution 2
An agent-based e-marketplace initiative
Solution Description
• Goal 2 – Provide initiatives for a non-linear,hub-based supply chain system
SOLUTION: Agent-Oriented Domestic e-Marketplace
Agent Oriented Domestic Marketplace
Figure 7: Logical concept of the Domestic e-Marketplace
Agent Oriented Domestic Marketplace
General Overview• Proposed e-Marketplace functions
– Will be able to support a broader base of services given further growth in e-Market infrastructure
– Baseline interaction and directory services– Specialty market services, such as:
• Dynamic trading;• Cooperative supply chain integration
and management– Enables and facilitates the relationship between
business participants• Suppliers and service providers; and• Supporting systems
Agent Oriented Domestic Marketplace
• Proposed e-Marketplace functions (contd.)– Many-to-many relationships supported between TMCA
and these business partners.– Enables both TMCA and suppliers to leverage
economies of scale in their trading relationships– Allows access to a more liquid marketplace
• Further allows the use of dynamic pricing models– e.g. Auctions (one of the services provided in
the proposed e-marketplace)– Improve the economic efficiency of the market
where uncertainty about prices and demands are common.
Agent Oriented Domestic MarketplaceIntegration with existing systems
• e-Marketplace architecture accommodates and supports interfaces to the existing business models of the participant entities through cooperative supply-chain integration and management– To provide smooth and effective integration at the business
level
• There is a need for well-accepted interoperability standards, which must be meshed for supply chain integration to meet business demands.
• e-Marketplace corresponds with the supply chain with flexibility and agility in responding to customer demand shifts without conflicts in resource utilization.
Integration with existing systems (contd.) • Fundamental objective improve coordination within
and between various participant business entities in thesupply-chain
• The increased coordination can lead to:– Reduction in lead times and costs– Alignment of interdependent
decision-making processes– Improvement in the overall performance of each
participant in the chain as well as the supply chain itself.
Agent Oriented Domestic Marketplace
Agent Oriented Domestic Marketplace
Integration with existing systems (contd.)
Figure 8: Logical concept of system Integration.
Agent Oriented Domestic Marketplace
Agent-Oriented e-Marketplace• Handles complex and non-deterministic interactions
usually involved in e-Marketplace– E.g. Auctions and ad-hoc service integrations
• Components of proposed e-Market system for TMCA will be able to change its configuration to participate in different, often simultaneous roles in e-Marketplaces.– Completes tasks that would be manually impossible.
• e-Marketplace agents play several roles– Will be able to coordinate, cooperatively or
competitively, with the other agents, including HR
Figure 9: The architecture of the e-Auction within the proposed e-Marketplace
Agent Oriented Domestic Marketplace
Agent Oriented Domestic Marketplace
Agents for the proposed e-Marketplace: • User interface agents
– support and collaborate with users in the same work environment to achieve the users’ goals
• Business-specific service agents– Specialists that provide a collection of business-services available in
the e-Marketplace– Performing the functionality of a business service is typically the
cooperative integration of several agents including:• business-specific service agents; and• market service agents
– Acts as a representative in the e-Marketplace for some functionality that is based on legacy applications or libraries, such as a product catalogue web site
Agent Oriented Domestic Marketplace
Agents for the proposed e-Marketplace (contd.) • Market service agents:
– Specialises in providing a collection of functions for generice-Businesses in e-Marketplace environments in which a single entity (usually an agent) can perform its tasks in the e-Marketplace.
– Market services (value-added and core services) are horizontal,i.e., services that are used in several business domains by several business entities.
• Integration service agents– Also provide a collection of integration functions for a cooperative distributed
system in which a single entity (agent, component, object, etc.)can perform its tasks.
– Used by several distributed entities. E.g. a brokering agent provides a capability-based integration service in the e-Marketplace.
• Another type of integration agent provides view-integration,which is a service to merge and map the description of business-objects (e.g., source schemas) in the e-Marketplace supported by the business ontology into an integrated view or schema
Agent Oriented Domestic MarketplaceReasoning behind Goal 2 – The Business Needs• The acquisition process of parts, materials and supplies from
TMCA’s 100+ suppliers can be slow, expensive and ineffective
• A “milk run” system could be possible within thesegroups of suppliers.
– No coordination among suppliers have been established Currently a missed opportunity
• Current electronic Kanban (card) system is the only existing mechanism for ordering supplies between TMCA and its suppliers;
• A linear supply chain is not able to efficiently support the JIT productions as significant collaboration among entities within the supply chain.
• For these reasons an agent-based e-marketplace initiativewill be suitable
– TMCA will be able to eliminate its existing linear supply chain system to permit supplier collaboration and integration.
Topic Outline
Solution 3
Real Time Inventory Tracking Module
By Nurhazman Abdul Aziz
Solution 3 :Real Time Inventory Tracking Module
Why did introduce this module?
• GOAL 3: Provide real-time updates on demand and supply allocation
• Solution: Real-time tracking function module incorporated into the current electronic BEA system
General Overview
• A complete modular solution,• reduce the bullwhip effect which causes
shifts in orders up and down the supply chain,
• eliminating any stockpiling cause by the current forecast method of determining the quantity of components needed for the productions.
General Overview
• to provide process visibility across the value chain, giving suppliers greater control over the process and
• ensure synchronization of information with all partners regardless of size or geographic location.
Graphical Overview
The Real Time Inventory Tracking Module
• To be incorporated into the BEA system, which comprises of 4 agents
– Forecast Agent– Inventory Agent– Order Agent– Multi - Tier Visibility Agent
Details of the Desired Agents to be work as
Forecast Agent • enables suppliers to rapidly align demand and supply in the mid-to-long-
term planning horizon, • allowing customers and their partners to arrive at a consensus forecast or
plan.• provides alerts and notifications of demand supply mismatches and • can support a single-phase or two-phase commit planning process.
Inventory Agent • enables suppliers to align demand and supply by providing visibility to
inventory status levels at multiple internal and external locations, as well as in-transit positions, enabling optimal levels of inventory.
• allows partners to exchange key inventory-related information, such as demand-pull requests and target inventory levels
• can be used to track supplier compliance to contract obligations such as min/max inventory levels.
• exception alerts can be configured to flag any inventory-level violations.
Details of the Desired Agents to be work as
Order Agent• enables suppliers to manage and track the entire purchase order lifecycle
through TMCA’s supply process. • Suppliers can manage and track, in real-time, the complete end-to-end
process for discrete, replenishment, demand pull and/or blanket purchase orders from order creation through shipment, receipt, invoicing and payment.
Multi-Tier Visibility Module • allows TMCA to extend their demand/supply planning, order management
and inventory management workflows beyond their first-tier partners to provide visibility to the processes executed between tier two, three and four partners.
• allows to monitor demand/supply disconnects and exceptions throughout the extended supply chain,
• providing tools to help identify the impact of problems identified multiple tiers away.
A Suitable Scenario
• The interest of this system is focused on a complete solution to provide a real-time updates on the demand and supply allocation.
• one of the distributors of TMCA has just received an order of purchase of a locally made Toyota Camry.
• logs the order into the current BEA system, the information will immediately be sent Toyota Vehicle Order Processing System (TVOPS).
• the real-time inventory module will acquire the new order information and be analysed.
• sent to the respective suppliers to be updated onto their own system.
• With such message flow, suppliers can get their supply ready for the next delivery to meet the JIT production in the shortest possible time needed.
Topic Outline
Solution 4
An agent-based transport and logistics coordination system
Solution 4
An agent-based transport and logistics coordination system
Why did introduce this module?
• Goal 4: Vertical industry logistics collaboration
• Solution: An intelligent logistic coordinating agent in the form of a
collaborative e-logistics hub.
General Overview
• An agent-based transport and logistics coordination system (collaborative e-market), are designed to accomplish transport and logistic coordination tasks among different automotive manufacturers in Australia.
• Consist of 4 generic roles agents in supply chain:• Distribution Hub Agent • Logistics Coordinator Agent, • Manufacturer Agent • Transporter Agent.
Framework for agent based supply chain coordination
The Distribution Centers of individual automotive manufacturers will send their distribution requirement (DRP) to a Logistics Coordinator who will transform the DRP into transport and manufacturing requirements.
These requirements will be broadcast to the available transporters and manufacturer’s plants so that they could work on their bids.
After the bids are received, the logistics coordinator will work on a global optimized solution before committing the distribution centers.
Logistic Optimisation within Australia
How does the logistics optimisation works within Australia:
• Based on ordered demand established, the Distribution Hub Agent calculates the distribution requirements.
• pass the DRP to the Logistics Coordinator Agent by pre-defined data interface. logistics coordinator splits the requirement into manufacturing and transportation requirements.
• Logistics Coordinator Agent divides the distribution requirements based on a historical knowledge base.
• In this database, the records show for a product, how long it will take for the Manufacturing Plants to produce a specific quantity, and how long it will take for the Transporters to deliver as shown in Table next
Logistic Optimisation within Australia
5. In the first round of coordination, the “Price” afforded by the Distribution Center is not given to the Manufacturing Plants and the Transporters.
6. Instead, the Logistics Coordinator waits for the service providers to bid with price.
Logistic Optimisation within Australia
• The Transporter Agents perform local optimization using their own data on routes, schedules and consignments.
• The Manufacturer Agents will perform local optimization using data on inventory, capacity and processing times.
• The results of the optimization will be transferred to the Logistics Coordinator Agent for global optimization.
Global Optimisation
• After the Manufacturer and Transporter Agents finish local optimization process, they will commit the orders back to the Logistics Coordinator Agent.
• to combine the respective commitments to produce joint commitments by summing up price and lead times (for Q1, Q2 and Q3 respectively)
Global Optimisation
• The optimization searching process is to find the optimal point (see Figure 12) which with acceptable difference with that of the customer requirement (with quantity, price and due date).
• If the point identified is still not acceptable, a boundary box will be defined around the optimal point to set the lower and upper limits so that a second round of bidding can be done. This process will be repeated until the solution converges.
A Suitable Scenario• The interest of this system is focused on improving the current logistic
demand to provide customers with the fastest delivery of their vehicles.• wish to send 20 cars to a country. • not feasible for TMCA to ship the cars.• With the system, TMCA invites other automotive manufacturers to join
collaborative e-logistic marketplace.• individual automotive manufacturers will submit their orders to the e-
marketplace.• Together with the shipping information provided by the freight companies,
the system will conduct an optimization searching process based on manufacturer’s requirements (quantity, designation, price and due-date) and the shipping details until the search has reached a optimal point when is feasible for the shipment to be made to the country or even nearby ports with the least time needed for the vehicles to arrive to their final designations.
Integrating the four solutions in a big solutions
Integrating is made possible• In order to overcome the weaknesses as previously identified, the team have provide
with individual solution to address each weakness.
• the proposed solutions are based on open standards means that is inherently easy to modify.
• designed to be flexible,
• allows the stakeholders to decide on which system is to be integrated and which system to be run alone.
• Additionally, exposing functionality and data as services across the enterprise also helps TMCA reduce overhead by eliminating the need for infrastructure duplication.
• the messaging-oriented nature of these solutions enables the team to link sales, marketing, manufacturing, and financial applications in real-time, which improves customer service by making up-to-the-minute information accessible across our value chain.
• Therefore, the team strongly suggests the implementation of the integrated solution.
Topic Outline
Financial Analysis
By Loh How Whay
Financial Analysis
• Increased ROI on Existing System
– Toyota’s WebLogic platform
– WebLogic development environment is built on the standards-based Java 2 Enterprise Edition (J2EE) platform
Financial AnalysisDevelopment Cost
Team of developers required by TMCA:Team of developers required by TMCA: 11 Project LeaderProject Leader 2 2 System Analysts System Analysts 10 10 ProgrammersProgrammers SALARIES AND WAGES
Team member Salary/wages for project
Project Leader $50,000.00
Senior system analyst $35,000.00
System analyst $30,000.00
Programmer analysts $60,000.00
Programmers $160,000.00
System programmers $50,000.00
Total salaries and wages $385,000.00
Financial Analysis
Development Costs GraphDevelopment Costs Graph
SUMMARY OF DEVELOPMENT COST
Expenses Amount
Salaries/wages $385,000.00
Equipment/installation $100,000.00
Trainning $200,000.00
Facilities $120,000.00
Utilities $70,000.00
miscellaneous $100,000.00
Licenses $10,000.00
Support Staff $50,000.00
Total $1,035,000.00
Financial Analysis
SUMMARY OF ANNUAL OPERATING COSTS
Recurring expense Amount
Connectivity $50,000.00
Equipment/installation $20,000.00
Programming support $80,000.00
Training & ongoing assistance $120,000.00
Advertising $50,000.00
Total recuring costs $320,000.00
Annual Operating Costs Annual Operating Costs GraphGraph
Financial Analysis
Sample Benefits GraphSample Benefits Graph
SAMPLE BENEFITS
Benefits/cost saving Amount
Increased localization of parts $300,000.00
Efficiency and flexibility in dealing with suppliers. $200,000.00
Reduced shipping costs $250,000.00
Increased sales of cars/parts $1,300,000.00
Other savings $100,000.00
Total annual benefits $2,150,000.00
Topic Outline
Net Present Value&
Return of Investment
NPV & ROI
Topic Outline
Financial Challenge
Financial Challenge• PROJECT COST
– Professional constraint programmers + months of development time– Significant investment amount from TMCA.
• THE NEED TO TRAIN INTERNAL AND EXTERNAL USERS– Company staff, suppliers, customers, automotive manufacturers, etc.
• PROPER INFRASTRUCTURE NEEDS TO BE PROVIDED– Users need to be capable of operating the system
with minimal technical support– Requires a significant amount of time and money
• Crucial to ensure project success.
• THE NEED TO RETAIN SYSTEM EXPERTS– None of required skills currently available to develop/support the system
• PREPARING FOR POSSIBLE OUTCOMES – Toyota should be prepared for project failure– A contingency plan
• fallback to other alternatives e.g. AANX.
Topic Outline
Organisational Challenge
Organisational Challenge
• COLLABORATION WITH PROJECT TEAM– IT staff to work closely with the development team
• Business requirements and project goals to be met– Constant communication between the development team and TMCA staff
• COLLABORATION WITH AUTOMOTIVE MANUFACTURERS, SUPPLIERS & CUSTOMERS
– Crucial requirements need to be identified → successful solution – Effective system use by users
• FOSTERING NEW RELATIONSHIPS– Marketplace will open up to potential customers and business partners
• Vertical/Horizontal industry • Requires better customer & supplier relationship management
• ADVERTISING THE NEW SYSTEM– Internal and external users mist be informed of new system
• E.g. automotive manufacturers, suppliers & customers
Organisational Challenge
• TRAINING USERS WITH NEW SKILLS & KNOWLEDGE– TMCA Needs to provide proper training methods to both internal and
externalusers of the system;
– USERS: Internal staff, suppliers, manufacturers & customers.
• ACHIEVING GLOBAL REACH– International market remains major challenge for TMCA
• CONVINCING TMC TO ADOPT THE SYSTEM – Pressure on TMCA for successful and reusable implementation
• MONOPOLY ISSUES– Blackbox method– Solution 4 will be an optional solution which requires careful
consideration
Financial Feasibility
• 6 months to develop and deploy→ Complexity
• Benefits– Shipping cost reduction;– Higher percentage of parts localization;– Increased profitability;– increased efficiency;– etc.
Topic Seminar
Cost Benefit Analysis
CostCategories of Cost Significant Major Minor
Development/maintenance costs X
Getting existing suppliers to use the system X
Reduction of shipping cost X
Attracting new suppliers X
Disruptions to staff X
Additional staff to handle the system X
Threat of competitors taking advantage of similar technology andachieving similar efficiency improvements.
X
BenefitsCategories of Benefits Significant Major Minor
Increased localization of parts X
Expanded sales and customer base X
Efficiency and flexibility in dealing with suppliers. X
Gaining experience that would assist with future e-commerce ventures. X
Increasing the business’ competitive advantage X
Suppliers remain loyal due the range of services offered X
Organizational Feasibility
• New solution to work in tandem with the existing system– Phased installation
• Ensures that organisational operations will not be affected dramatically during implementation.
• Relationship between Toyota & suppliers improved→ higher degrees of collaboration
→ System Introduction Highly Feasible
Conclusion
• The study is being conduct in procedural manner. • Focus on current supply chain and what the current IT
setup exist• Weakness were identified based on overall supply chain
process• Goal are set to close the current gap of inefficiency
identified.• Based on each goals, solutions are derived.• To prove worthiness of each solution, illustrates in terms
of business needs are provided. • Other factors, such as challenges and financial, have
proofed feasible for these proposed solutions to be implemented.
Q & A Session