Notes
Slide Show
Outline
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Distribution Network Redesign
  • Logistics Network Inc.
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Project Definition
  • Issue: As a consequence of price erosion on the client’s products as they became more commoditized, it became essential for them to preserve margin through cost efficiencies.
    • Due to temperature constraints, they deliver a particular product line via air freight.
    • Because of the numerous distributor sites in place, they relied heavily on LTL delivery, rather than truckload.
  • Objective: Reduce freight costs without negatively affecting service.


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Primary Metrics
  • Freight cost per unit of sale (lbs.or gm.)
  • On-time delivery performance
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Sales Distribution by State - $$$
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Sales Distribution by State (%)
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U.S. Sales by State
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Canadian Sales Distribution
 by Province – (%)
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Canadian Sales
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Mexican Sales Distribution by State
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Mexican Sales
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Preliminary Facts
  • Total Freight Expense:  $1.93 mil. (net after prepay and add)
    • Approx. Int’l Freight: $150k
    • Net N.A. Freight: $1.78 mil.
      • Prepaid Distributor Freight: $915k – 51%
      • Prepaid Direct Freight: $865k – 49%
  • Freight Terms:
    • 33% Prepaid
    • 67% Customer Paid (Prepay & Add/Collect)

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Additional Supporting Facts
  • Overall Mode Mix
    • 28% Air/72% Ground ($490k/$1,281k)
  • Prepaid Distributor Mode Mix
    • 19.5% Air/79.5% Ground ($178k/$737k)
  • Overall Freight/Sales Ratio: 1.5%
    • Total Freight Paid/Total Revenue
    • Below 2% is considered quite good.
  • Prepaid Freight/Sales Ratio – 4.6%
    • Total Freight Paid/Revenue Associated with Prepaid Freight Transactions
  • Cost Comparison – Freight Modes ($/lb.) Average:
    • Air $1.00/lb.
    • LTL Truck $0.10/lb.
    • TL Truck $0.08/lb.

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Considerations
  • Under the present model, for every $100 in additional distributor sales, where client pays the freight, their freight costs increase by $4.60.
  • Converting to prepaid distribution $8 mil. of additional tier three direct business, currently moving on a collect basis, would cost client $368k (based on current freight ratios).
  • If a significant amount of our current direct business is converted to distribution, they could, under the present model, incur a substantial increase in freight costs.


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Process Improvements
  • Consolidate deliveries to partners on a weekly basis with shipment via truck, rather than air.
  • Reduce the number of ship-to locations to maximize the opportunity for consolidation.
    • Present distributor network displays many apparent redundancies.
    • The fewer ship-to locations, the more opportunities for consolidation of shipment and reduced freight costs.


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Site Recommendations
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Project Recommendations
  • Migrate from 15 to 5 distributors
  • Reduce number of distributor locations from 39 to 9
  • Increase reliance on truckload vs. LTL
  • Increase reliance on refrigerated surface transport vs. air shipment
  • Position distributor sites to maximize opportunity for next day surface delivery to our customer base
  • Under proposed model, surface delivery is possible to virtually every point in the continental U.S.
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Project Summary
  • Reduced the number of distribution sites, simplifying the process. (Soft costs not calculated.)
  • Maintained service levels to the customer.
  • Reduced freight costs from $1.78 million to $1.51 million (15% - $271K)