Moving production back

The Economist, April 2012. The third industrial revolutionThe article in the April 21st edition of the Economist indicated the underlying costs for an Apple iPad. In studying this information, I continue to be amazed about a point that many miss: that materials costs are the largest element, accounting for 44% of the costs and 31% of the sales price. Direct labor and overhead are miniscule. Distribution and retail costs are 22%of the costs and 16% of the retail price.

The implications of this information are profound: companies in the U.S. are the most advanced in the concept of purchasing and supply management. We can find materials locally and produce locally and not pay the high costs of transportation, have less flexibility in the use of materials, and can have better inventory positioning.

I have made this case before. Is anyone listening? I can show from a total cost standpoint that U.S. manufacturers can be competitive, even more competitive, than Asian and Chinese suppliers. We need to change the mindset about this to improve control, cost management, and flexibility.

Why Supply Chain Planning Matters

The current crisis in Japan underscores the need for proper contingency planning in supply chain management.  Far too often companies are unprepared for major supply disruptions, causing product and service shortages and leading to significant price spikes.  Supply chain managers should consider these risks, however remote they may be, and develop contingency plans that can be put into action quickly to reduce the impact of localized supply disruptions.

To be effective these back-up plans should consider the levels of impact that are possible depending on the scale of the emergency.  Additional sources of supply should be found in geographically separated locations.  It does no good to have alternative suppliers if they are all faced with the same natural disaster, as appears to be the case in the electronics industry at present.  It is also important to test your contingency plan in advance to ensure that it will be an effective response and adequately maintain your continuity of supply.

How your supply chain responds in moments of crisis and supply shortage can provide signifcant competitive advantage around price and availability.  It’s worth the long-term investment in  some emergency preparedness planning.

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