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Supply chain management six sigma: A management innovation methodology
at the Samsung Group
Article in Supply Chain Management · March 2007
DOI: 10.1108/13598540710737271
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Insight from industry
Supply chain management six sigma:
a management innovation methodology at the
Samsung Group
Hong Mo Yang, Byung Seok Choi, Hyung Jin Park, Min Soo Suh and Bongsug (Kevin) Chae
Samsung SDS, Sungnam-Si, South Korea
Abstract
Purpose – This paper seeks to introduce a six-sigma based methodology for the SCM domain which was developed and has been used in Samsung.
Design/methodology/approach – The paper provides a detailed description of how and why a six-sigma-based methodology for the SCM domain
was developed in Samsung and presents a real industry case to illustrate the usage of the methodology.
Findings – In Samsung, the effort and investment in synthesizing SCM and six sigma, and developing a unique six-sigma-based methodology to
improve its SCM operation, have turned out to be fruitful. The Black Belt program has produced highly qualified and talented SCM specialists, who are
currently training the methodology to members in their organizations and leading SCM projects. SCM projects are being prepared and conducted in a
more disciplined way and their outcomes are continuously monitored and shared through the company’s repository.
Research limitations/implications – To generalize its usefulness, the methodology needs to be applied to the SCM projects of those companies
whose organizational and cultural contexts are different from those of Samsung. In addition, the overview of an illustrative SCM project presented in
the paper is brief due to space limitations.
Practical implications – Today, SCM is increasingly recognized as a strategic way to innovate a company’s business operation. This paper shows that
a methodology such as Samsung’s SCM six sigma can be the key to conducting SCM projects in a more disciplined way and for fruitful outcomes.
Originality/value – The paper introduces a unique six-sigma-based methodology for the SCM domain which has been developed and applied in a
leading global manufacturing, financial, and services conglomerate. This methodology could be adapted by other companies for their SCM projects to
increase the likelihood of project success.
Keywords Six sigma, Supply Chain management, Project management
Paper type Case study
Samsung. The next section describes a detailed overview of
the Samsung SCM six sigma methodology, which has been
used for the last two years. A summary of a six sigma supply
chain project is then presented and in the final section we
draw some conclusions.
1. Introduction
In its early years, supply chain management (SCM) was
narrowly conceived as a new approach to inventory
management or operating cost reduction. In the 1990s
organizations and some specific industry segments began to
recognize the much greater roles and impact of SCM on their
business operations. SCM is increasingly recognized as a
strategic way to innovate a company’s entire business
operation as well as its planning and execution. This article
reports Samsung’s journey in developing a systematic SCM
methodology using six sigma and applying it to SCM projects
and related activities.
The article first presents the background of introducing a
six-sigma based methodology for the SCM domain in
2. Background
2.1 Company overview and the role of SCM and six
sigma
The Samsung Group of companies is recognized as a leading
global manufacturing, financial, and services conglomerate. It
was founded in 1938 and focused its businesses on areas such
as textiles, shipbuilding, machinery, and chemicals. Since the
1980s, the group has made enormous efforts and investment
in the electronics and semiconductor industry. As a result, the
Samsung Group has experienced a dramatic growth in net
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/1359-8546.htm
The authors thank Mr Banghwan Chung, Nackkyo Choi and Muyeol Seo
for kindly sharing with us their experiences and lessons learned from
applying SCM six sigma methodology in their SCM projects. We would
also like to recognize the enormous effort made by many members of the
SCM Business Team, including Mr JungGee Yoon and other SCM MBB/
BBs, in developing and teaching the methodology.
Supply Chain Management: An International Journal
12/2 (2007) 88– 95
q Emerald Group Publishing Limited [ISSN 1359-8546]
[DOI 10.1108/13598540710737271]
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Supply chain management six sigma
Supply Chain Management: An International Journal
Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
profits since the 1990s. The flagship unit, Samsung
Electronics Company (SEC), was one of only two
manufacturing companies worldwide to post profits of more
than $10bn in 2004 (Toyota Motors being the other).
Samsung was ranked twentieth in global brand value,
according to a report by Interbrand (2006). Many regard
these successes as reflecting a continuous and relentless effort
at Samsung to improve the way it conducts business. For the
last few years, SCM and six sigma have been two pillars of
business innovation at Samsung.
The Samsung Group of companies has large, complex,
global supply chains in most of the products it manufactures
and makes extensive use of SCM solutions and process
innovations to support and improve its operations. Most
notably, at SEC, advanced planning and scheduling (APS)
systems have been adopted since the 1990s and have brought
the company many successes in terms of operational
excellence. Recently, Samsung Electronics was ranked
seventh in a respected analyst’s ranking of the global top 25
companies in supply chain excellence (AMR, 2005).
Six sigma has been a key enabler for the group’s success. The
Chairman of the Group proclaimed the adoption of a business
innovation approach called “new management” (pronounced
in Korean as shin kyung young) in 1993. “New management” is
the pursuit of quality-oriented management in business
operations as well as in manufacturing. Along with the
“quality movement” in industry, new management evolved
from initial product quality assurance but later shifted its focus
to include the quality of the entire business process, which is
the rationale behind six sigma. The outcomes were highquality, innovative product developments, and consequently an
increase in customer satisfaction and profits, and are well
demonstrated by many of the world’s best technological
resources, including DRAM, SRAM, TFT-LCD, digital TV,
and Flash memory, to name but a few.
3
4
2.2 Why SCM 1 six sigma?
Despite the extensive use of SCM solutions and process
innovation to improve global business operation, in 2004 the
company still felt that its supply chain operations had
significant room for improvement. In the early 1990s, the
Group’s senior management decided to capitalize on the
potential synergy between SCM and six sigma, which they
believed were based on four key areas:
1 Project discipline – Six sigma uses a structured process of
defining, measuring, analyzing, improving, and controlling
(DMAIC) products or processes, which provides the
discipline to deal with operational vulnerabilities and
variability in business operation (Hammer, 2002). Six
sigma would enforce a more disciplined approach to SCM
projects and ensure that SCM projects were defined
rigorously and executed methodically. Also six sigma’s
analytical emphasis would steer the improvement projects
to investigating and resolving root causes, rather than mere
symptoms of SCM problems at Samsung.
2 Sustaining results – One of the key challenges of SCM is
sustaining the results of a successful project after
completion. Too often, as project groups move on to
future projects, the past process improvement successes
become just that – “past” successes – rather than a
sustained base of improvement on which to build further.
However, the link between planning and execution
through feedback (also known as closed-loop) has been
an important issue in SCM in general and manufacturing
planning and control system in particular (Vollmann et al.,
1997). Six sigma complements this need through the
“control” stage in a DMAIC methodology or “verify”
stage in a DMADOV methodology. Therefore, six sigma
supplemented by a Samsung’s own centralized system of
capturing and tracking all of its projects beyond their
completion ensures that improvements be sustained.
Well-established HR framework – At Samsung, a key area
for the potential improvement of SCM activities centered
on people. The company continually faces a shortage of
trained, qualified, and talented people to harness the
maximum potential that its systems and processes offered.
Consequently, SCM solutions were not being fully
utilized and the innovative processes could not be
wholeheartedly adopted. The shortage of SCM talent
decreased the potential for return on investment that the
system and process innovations could bring to the
company. Six sigma was seen as a proven framework for
developing people. Its colored belt system clearly
delineated levels of competency and thus helped manage
people in a differentiated way from the HR perspective.
Six sigma was already prevalent in Samsung as a
management innovation methodology with programs
and structures in place. Leveraging the belt system with
SCM expertise was a way to keep track of and continue to
develop SCM talent within the Group.
Quantitative strength – Six sigma was seen as a
methodology which would, by its nature, drive a
heightened usage of quantitative analysis (Breyfogle,
1999). Quantitative data about operational activities and
performance was abundant, but not used sufficiently for
problem solving or decision-making. Appropriate usage of
numerical data was expected to uncover flaws in SCM
processes and further enhance the quality of SCM
decisions made at Samsung.
Based on the above rationale, the company put together a
methodology to formally combine SCM and six sigma, by
training and developing supply chain staff to be more capable
of leading SCM innovations. Over the last two years of
implementation, SCM six sigma has become a unique and
useful component of Samsung’s strategy for systematic and
continuous improvement of its SCM activities.
3. Samsung SCM six sigma
Samsung SCM six sigma comprises two building blocks. The
first block is a core methodology that was developed by the
SCM Business Team (subsequently referred to as “SBT”).
This team researched various six sigma approaches of selected
global companies and then tailored its learning to the SCM
domain. The second element of SCM six sigma is some key
design principles derived from the team’s SCM experience
base to guide the implementation of the methodology
throughout its different stages.
3.1 Research and tailoring
SBT researched six sigma approaches at General Electric (GE),
since GE is a recognized global leader in six sigma.
Additionally, the team researched two other companies –
DuPont and Honeywell – to get perspectives on how other
companies have innovatively applied six sigma to similar needs:
89
.
.
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Supply chain management six sigma
Supply Chain Management: An International Journal
Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
General Electric – A key element of GE’s approach to six
sigma is the tailoring of underlying methodologies to
specific needs and characteristics of its business units.
SBT researched GE business that has taken the generic six
sigma methodology for process innovation (PI), and has
tailored them to specific needs of system design and
implementation, and product development activities.
Particularly, DMADV (define, measure, analyze, design,
and verify) by GE Medical System is an attempt to include
process management and process redesign in six sigma,
while moving beyond DMAIC (often regarded as a
synonym of six sigma), originally developed for highquality product developments (Hammer, 2002). GE
Capital’s DABTL (define, architect, build, test, launch)
is a six sigma approach designed for systems development.
DuPont – DuPont had just been selected as the 2006 Six
Sigma Company by the International Society of Six Sigma
Professionals (ISSSP) (Forloines, 2005). Additionally,
DuPont also combined six sigma principles with the
SCOR (Supply Chain Operations Reference) model,
which is a process reference model for SCM developed
by the Supply Chain Council and enables effective
communication among SCM partners. SCOR scopes
five core management processes, including plan, source,
make, deliver, and return (See SCOR Model 7.0 for
details). The use of SCOR for analyzing supply chains has
been of interest (Burgess and Singh, 2006). DuPont’s Six
Sigma approach utilizes a quality function deployment
(QFD) tool, a method or technique for converting
customers’ requirements to products, processes or
services.
Honeywell – Honeywell was selected because of its
extensive application of lean methodologies, which has
become a major tool in the implementation of six sigma,
as evidenced by the Proceedings of the ISSSP (2005).
Honeywell developed a proprietary Six Sigma approach
called Six Sigma Plus (DMAIC) which links lean
manufacturing concepts and tools (e.g. value stream
map, thought process map) into a general six sigma.
.
Group. DMADOV stems from a product design space
while one requirement is to support projects in the supply
chain space. The key difference is that after performing
analyses, the task for the project team would be not to
optimize or design as in DMADOV, but to specify how a
suggested improvement would be realized in practice.
Therefore, a step, “Enable”, in place of Design and
Optimize, is introduced to address this activity. This is
similar to “Design” in GE Medical’s DMADV.
System development option – SCM six sigma projects, in
most cases, result in system development. Accordingly, a
new approach is needed to cover a process enablement
step to support system building activity. However, many
SCM innovation projects may call for changes that can be
enabled within existing system capabilities. Therefore, it
was necessary to consider an approach in which system
implementation would be an optional enablement activity.
We used DABTL (define, architect, build, test, launch)
approach (used by GE Capital for systems development),
incorporating proven software engineering discipline to six
sigma based SCM methodology.
3.2 DMAEV
The resulting approach is termed DMAEV (define, measure,
analyze, enable, and verify) (Figure 1). Additionally, we
incorporated the concept of five design parameters (process,
operation rule & policy, organization role & responsibility,
performance measure, and system), process modeling and
value chain map techniques, and SCM related investment
value analysis methods.
The goal of the Define phase is to define the overall project,
including the problem(s) to be tackled, project goal(s) and
scope, expected outcomes, and project schedule. The first
step identifies key issues and problems through the voice of
the customer (VOC) and the voice of the business (VOB) as
well as the analysis of SCM related processes. This step elicits
customer’s critical to quality (CTQ) criteria or characteristics.
The next step finds the CTQ-dependent variable (Y). The
outcomes from the Define phase become essential for the next
phases.
The Measure phase identifies the current level of CTQ-Y,
sets up a new target level, and finds the key explanatory
variables (Xs). The first step verifies CTQ-Y and then, if
necessary, further identifies several specific indicators that can
substitute CTQ-Y. The next step measures the current level of
CTQ-Y and sets up an improved target level of CTQ-Y. The
following step elicits potential Xs (or causes of the problem)
with respect to five design parameters:
1 process;
2 operation rule and policy;
3 organizational role and responsibilities;
4 performance measure; and
5 system.
Each of the above approaches was analyzed and the following
conclusions drawn, which fed into the subsequent
development of the Samsung SCM six sigma methodology:
.
Nature of SCM projects may involve either design or
improvement – Six sigma projects usually focus on either
redesigning processes and systems or improving
performance levels of existing systems. In six sigma
parlance, the former is addressed most commonly through
DMADOV (define, measure, analyze, design, optimize,
verify), while the latter is addressed using DMAIC
(define, measure, analyze, improve, control). SBT
estimated that among the SCM projects at Samsung,
about 75 percent would involve re-designing processes,
while the remaining 25 percent would focus on process
improvement. Accordingly, extant six sigma approaches
were adapted in order to accommodate both redesigning
and improving processes. Consistent with the expected
mix of projects stated above, this new approach was closer
to supporting process redesign, but still incorporated all
relevant elements for process improvement.
.
DMADOV is not enough – The DMADOV methodology,
while useful, could not provide the necessary support to
execute the entire range of SCM projects at the Samsung
The Analyze phase generates and evaluates “hypotheses” as to
the potential Xs. This phase cycles between hypotheses and
fact-based analysis to prove or reject the hypotheses. This
process involves both quantitative and qualitative analyses for
evaluating hypotheses. The quantitative analysis includes
various statistical tools such as ANOVA, Pareto analysis and
correlation, while the qualitative analysis uses process
mapping, cause and effect diagrams and value stream maps.
In the end, the goal is to select the vital few Xs, representing a
few key explanatory variables.
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Supply chain management six sigma
Supply Chain Management: An International Journal
Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
Figure 1 An overview of SCM six sigma
The Enable phase identifies ways to improve the “as-is” and
develops a plan for the “to-be”. The quality function
deployment (QFD) is used to select the subjects for
improvement regarding the vital few Xs and to elicit
detailed action items for improvement. Several alternative
solutions are elicited, then the optimal solution is identified
through the use of AHP (analytic hierarchy process) methods
for improvement or the final to-be plan, which is further
detailed in terms of the five design parameters. If system is
required as part of the optimal solution, DABTL (design,
architecture, build, test, launch) is utilized for systems
development and implementation.
The Verify phase establishes a pilot test plan and then
validates and verifies the solution chosen in the Enable phase.
Next, control and change management plans are developed
and then the optimal solution is put into operation. The
methodology encourages a comprehensive change
management plan that supports the execution of the optimal
solution with respect to those five design parameters. The
results are continuously collected, monitored, and shared
through the Group’s repository for projects
Two kinds of measures or KPIs are used:
1 financial; and
2 operational.
.
.
.
.
global optimum;
process KPI mapping;
systematization; and
five design parameters (Figure 2).
The overall approach was designed to be easy to learn, apply
and maintain. Further, the approach had to be applicable
within the regular flow of work of supply chain personnel
working on their projects, to avoid them being involved in
additional project work:
.
Global optimum – SCM aix sigma improvements are
positioned not as narrowly focused functional
improvements but as improvements of the end-to-end
SCM process. All improvement ideas must be aligned
with global rather than local goals. That is, when
improving a process through SCM six sigma, it will be
necessary to measure, monitor, and, if possible, improve
key performance indicators (KPIs) of related upstream
and downstream processes. Thus, two mechanisms for
ensuring global optimization were utilized. First, before an
improvement is attempted, a flow-down tree of the
critical-to-quality KPIs (called CTQ-Y), in a hierarchical
structure using mega-processes and sub-processes, is
used. Later, after the improvement is piloted, a bottomup check is used to ensure that global KPIs have not been
adversely affected.
.
Process KPI mapping – Process KPIs follow the SCOR
Model, and are used to define objectives and monitor the
process towards managing improvement plan goals.
Compared to generic six sigma, SCM six sigma
increases the credibility of CTQ-Y selection using KPIs
decomposed by detailed supply chain processes of the
SCOR model.
.
Systematization – Systematization is viewed as a key
component of an SCM initiative at Samsung. Samsung
uses systems (e.g. advanced planning systems) extensively
to effect behavioral and process changes. Therefore, to the
extent that SCM changes need to be reflected in processes
and systems, systematization is a critical component of
SCM six sigma. This is achieved utilizing the DABTL
In general, the increases in sales, and the decreases in
material, inventory and transportation expenses that result
from the improvement and redesign of SCM are examples of
financial KPIs. Operational KPIs include cycle time,
utilization rate, lead time, forecast accuracy, etc.
3.3 Design principles
SBT realized that the success of the DMAEV methodology in
driving SCM innovation would depend on not only the
strength of the methodology itself, but also on relevant
business and organizational factors. Based on the SBT team’s
experience and expertise in business and organizational
aspects of SCM, the following design principles that would
guide SCM six sigma projects through all of the DMAEV
stages were drawn:
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Supply chain management six sigma
Supply Chain Management: An International Journal
Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
Figure 2 A summary view of Samsung SCM six sigma
.
(design, analyze, build, test, launch) roadmap for system
implementation, which incorporates proven software
engineering discipline into our methodology.
Five design parameters – The underlying belief is that any
organizational change requires a comprehensive, multifaceted approach. Thus, DMAEV uses the five design
parameters to characterize the changes that need to be
managed throughout the DMAEV process stages –
process changes; operation rule & policy changes; role &
responsibility changes; performance measures/KPI
changes; and system and master data changes. A project
will need to identify latency cause factors and
improvement plans for each of the parameters to ensure
comprehensive treatment of root causes.
techniques in that methodology in particular. To illustrate the
application of the SCM six sigma methodology in practice, this
section presents a brief overview of a SCM project conducted
in a manufacturing firm (its name and detailed information are
not revealed). This project, completed in the early 2006, had
applied the methodology from its beginning in 2005.
4.2.1 Define
The VOC/VOB analysis began with investigating internal and
external business environments and identifying clients of the
project. Increases in crude oil price and the devaluation of the
Korean won represented a challenging external business
environment while an increasing cost associated with surplus
inventory was a critical pain point. Top management and
various business units including sales, planning &
administration, production, purchasing, global operation
center (GOC), and transportation in the company were
identified as the project’s clients. Then, the VOC/VOB was
elicited from interviewing those business units (Figure 3).
The next step was to identify problems and inefficiencies in
SCM-related business processes, typically encompassing
production (e.g. material purchasing, manufacturing), global
operation management (e.g. order fulfillment, weekly
production plan, inventory management) and sales (e.g.
forecasting, order management, sales, transportation). Eight
issues were identified, including a lack of visibility in inventory
and demand forecasting, in the process of replenishment,
weekly production planning and packing & shipping. Drawn
from the VOC/VOB and process analysis, two potential CTQs
were elicited:
1 demand stabilization; and
2 inventory visibility.
4. Adoption of SCM six sigma at Samsung
There are two courses in implementing SCM six sigma
methodology at Samsung: education (“SCM Six Sigma Black
Belt”) and application of the methodology in practice.
4.1 SCM Six Sigma Black Belt
The first course is the institutionalization of the methodology
at the Group through a four-month training program. The
training program, known as SCM Six Sigma Black Belt
training and mentoring, consists of one week per month of
full-time training for four months, supplemented by
mentoring of SCM Black Belts on their selected projects.
The prospective SCM BBs have to complete three such
projects to get full certification as a SCM Black Belt.
By leveraging the established HR belt system of six sigma,
Samsung aims to alleviate the shortage of SCM talent that has
been the primary obstacle in improving SCM performance.
Samsung expects that SCM six sigma will elevate the
effectiveness of its SCM function as people will now
understand the overall supply chain process and ways of
enabling it. Samsung also expects that greater effectiveness of
its people in managing its supply chains will improve the
company’s ROI. The current training program is within the
Group’s Six Sigma Academy, the goal of which is to develop
talent and future leaders at Samsung. As of today, over 100
SCM Black Belts have been trained.
The priority of these two was evaluated with respect to the
findings of the VOC/VOB and process analysis. As a result,
the latter (development of inventory management process)
was chosen as the CTQ and surplus (or unpegged) inventory
rate, defined through the formula:
X
X
Unpegged inventory= Inventory £ 100;
was selected as CTQ-Y (or the key performance indicator of
the CTQ).
4.2 An illustrative case
As of 2005/6, SCM projects at Samsung are being conducted
by following the SCM six sigma methodology in general and
utilizing DMAEV and various data and process analysis
4.2.2 Measure
The baseline level of surplus inventory rate was measured to be
over 10 percent. A new target was set at 6 percent. This required
a 42 percent reduction in surplus inventory. Next, potential root
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Supply Chain Management: An International Journal
Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
Figure 3 Summary of the VOC and VOB
causes or Xs were identified in terms of the five design
parameters, (process, operation rule & policy, organizational
roles and responsibilities, performance measure, and system)
and further prioritized using an X-Y matrix (Table I).
After considering the importance by the project owners,
including representatives of the client groups, finally, seven
causes associated with three parameters – process, role &
policy, and system – were selected as the final Xs (Table II).
Table I X-Y matrix
Type of
parameter
CTQ
Development
Evaluation of inventory
Quick
management
criteria
Type of X
C
N SOP win Importance
process
Prioritization
Percentage
Total
rank
Potential cause (Xs)
X
Reflecting quick demand
Inputting weekly demand data
Recording past surplus inventory
Planning surplus inventory consumption
Early detection and advanced managing of
surplus inventory
U
U
U
U
3
3
9
9
3
3
9
9
3
3
10
10
U
9
9
10
Rule & policy
Standard for demand inputting
Standard for reflecting quick demand
Standard for managing excess inventory
Standard for managing surplus inventory
Standard for managing safety stock
U
U
U
U
U
3
3
9
9
9
3
3
9
9
9
3
3
10
10
10
System
Web user interface design
Inventory name management
Amount search capability
U
U
U
9
3
1
9
3
1
10
3
1
Roles and
responsibility
New job position for stock management
Sales and demand control and management
Rearrangement of stock management tasks
1
3
1
1
3
1
1
3
1
Performance
measure
Reduction of demand change rate
3
3
3
Process
U
U
U
U
Notes: Types of Xs include C (constant variable), N (noise), X (controllable variable), SOP (standard procedure), and Quick-Fix (variables that can be fixed
quickly). Importance: 1 (low impact on Y), 3 (medium impact), 9 (high impact)
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Hong Mo Yang et al.
Volume 12 · Number 2 · 2007 · 88 –95
(Figure 4). Then, using benchmarking, the to-be image for
each of the three possible solutions was developed. Then,
“Web-based user interface design for inventory management”
was found to be highly relevant to the overall improvement
subjects identified in the QFD. To design and implement the
selected optimal solution (named “Web-based early warning
system for surplus inventory”), necessary changes were
identified with respect to the five parameters. For example,
as to the “process” parameter, a list of processes which
needed to be improved was identified.
As for the “system” parameter, DABTL was employed to
define system requirements and to architect, build, test, and
put the web-based system into operation.
Table II Selected Xs
Type
Selected Xs
Process
Recording past surplus inventory
Planning surplus inventory
Early detection and advanced managing of surplus
inventory
Rule & policy
Standard for managing excess inventory
Standard for managing surplus inventory
Standard for managing safety stock
System
Web user interface design
4.2.5 Verify
Two stages of pilot test were conducted with a business unit in
the company. The first stage, which took place in October
2005, aimed to prove the applicability of newly proposed or
improved processes, rules and policies, roles and
responsibilities, and performance measure. The pilot test of
the system was excluded during this stage. The second stage
piloted all improvement subjects associated with the five
parameters between 9 January and 28 January 2006. The pilot
test resulted in a 37 percent reduction in surplus inventory
(CTQ-Y), from 10.4 percent to 6.5 percent. Although slightly
short of target, the cost associated with surplus inventory
decreased from over $2.7 million to $1.9 million.
Next, in order to proceed and accelerate the adoption of the
optimal solution, “control” plan and change management
plan were developed. The control plan included factors or
performance indicators (e.g. inventory consumption rate) to
be controlled, methods to control, business unit responsible
for each factor, and actions to be taken for unexpected events.
The change management considered such elements as critical
4.2.3 Analyze
For those selected Xs, data collection was planned and
executed (Table III). For each question posed in Table III, a
detailed data analysis was conducted, including both
quantitative (e.g. graph, statistics) and qualitative (e.g.
benchmarking, Delphi method, on site visit, document
review) tools.
Based on the results of the data analysis, three Xs –
recording past surplus inventory, standard for managing
excess inventory, and web user interface design for inventory
management – were determined to be the vital few Xs. These
were the factors considered to significantly affect the CTQ-Y.
4.2.4 Enable
The three vital few Xs led to three possible solutions or
actions to improve the current SCM. For each solution or
action, detailed improvement subjects were elicited with
respect to the five parameters. This overall information was
constructed through a quality function deployment (QFD)
Table III Plan and execution of data collection
Data collection plan
Data collected
Selected Xs
Questions
Analysis tool
Data source
Early detection and
advanced managing of
surplus inventory
Is managing surplus inventory done weekly?
Graph
SAP R/3
January 2004-August 2005
Unpegged inventory, dumped
inventory
Recording past surplus
inventory
If recording past data of excess, surplus,
dumped inventory is done weekly, not
monthly, does this have a positive effect on
the overall inventory management?
Research on site
Relevant documents
Relevant Excel worksheets
Planning surplus inventory
consumption
If managing excess, surplus, dumped
inventory is done weekly, not monthly, does
this have a positive effect on the overall
