Materi PT Bayer Indonesia
Materi PT Bayer Indonesia
Materi PT Bayer Indonesia
COVID-19 Pandemic:
Leveraging S&OP
Through Strategic
Partnership With
Suppliers
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16 September 2021
Adrin Ramdana Rauf
Agenda
Introduction
Detecting Disruption
Reducing Vulnerability
2018 – Sep’21
2007-08
2012 2016-18 2018 Head of
2007 2008-10 2011 2013-16
2010-12 2012-13 2015 Supply Chain
Management Management
Trainee Graduated Supply Chain Master
Graduated Continuous Lean Six Operational
Manufacturing Procurement Hoshin Kanri Manager Scheduler for
Agro Industrial Improvement Sigma Black Excellence
Manager Master of Manager Facilitator Consumer & North America Mar 2021-now
Engineer Production Coach Belt Manager Pharma & Mexico
Planner Management
Head of
Operations
6 months
3 /// Bay er Indonesia // PQM 6 months 1 month
Detecting
Disruption
A Proactive Approach For
Predictability
> 12 mio confirmed cases ▪ The global impact of the 2019 coronavirus disease
(COVID-19) has been well reported
> 0.5 mio confirmed deaths
▪ Many countries have thus imposed pandemic suppression
measures such as lock-downs and community quarantines
216 countries, areas affected in an effort to stem the progress of the pandemic.
5 /// Bay er Indonesia // PQM
Complex Network of Global Supply Chain in Consumer Health
Industry, particularly for Bayer site in Indonesia
Early wave of COVID-19 pandemic had signaled a forthcoming supply chain disruption
6
Data Driven Assessment
Risk level scale (RLS) is calculated using equation (1) as follow:
RLS = (rLT x wLT) + (rSL x wSL) + (rMQ x wMQ) + (rRS x wRS) + (rSC x wSC)
rLT : Lead Time risk rating
COVID-19 impact on: wLT : Lead Time weight
rSL : Shelf-Life risk rating
wSL : Shelf-Life weight
Table 1. Risk Level Scale
rMQ : MoQ supply coverage risk rating
Logistics • E- mail & phone
survey in Feb- wMQ : MoQ supply coverage weight
Risk Level Scale
Mobility May 2020 Low 1.0 - 3.6
rRS : Regulation Status risk rating
Medium 3.7 - 6.3
wRS : Regulation Status weight
• ABC analysis for Finished
High 6.4 - 9.0
rSC : Sourcing Complexity risk rating
Goods
Materials • Bill of Material explosion for A wSC : Sourcing Complexity weight
Supply Risk class Finished Goods (FG)
• Risk Level Scale (RLS)
Assessment assessment through
Consensus Oriented Decision Table 2. Evaluation Criteria for Raw Materials Supply Risk Assessment
Making Rating
Parameter UoM Weight
1 3 5 7 9
Regulation
Non-regulated NA NA NA Regulated NA 0.2
Status
Single sourced - Single sourced
Ongoing Single sourced
Dual sourced with however with non-commodity/
Sourcing qualification of commodity with
different parent- multiple specialty with NA 0.3
Complexity second various potential
companies manufacturing sites limited potential
manufacturing-site suppliers
of same supplier suppliers
7
Understanding Logistics Mobility Disruption
▪ Air freight frequency was > 30% higher in 2020 vs YoY 2019
4%
Table 5. ABC Class Analysis result from 149 FG SKU to be produced by 18%
The Company for the next 12 months
% to annual
Item Class volume Count of SKU % to total SKU
A 70% 26 17%
B 21% 43 29%
C 9% 80 54% 78%
Reducing
Vulnerability
Downstream
Control Control
Tower Tower Logistics Service Provider
Global API Hub
Logistics Service Provider
Cust
PRO SCM
Shortening Forecast Horizon
Center of Gravity
Critical Material Suppliers Product Supply Center - Cimanggis
Capacity
Workforce
Company affiliates
Inventory at country of destination
(incl.PPE)
GROWTH
Nut-b
Digestive Health 3
Nut-c
Medicated Skin Care
2
Allergy Criteria:
• Growth (1-5)
Cardiovascular • # of Countries (1-5)
1
• Volume (1-10)
0
0 1 2 3 4 5 6
# of COUNTRIES
14 /// Bay er Indonesia // PQM
Counter Measures to mitigate the vulnerability
The mitigation was classified into three level according to the urgency and execution timeline
Forecast
Aggregation
3-12 months
Tactical Inventory
Redundancy
• Product family convergence showed Nutritional category as the focus in pandemic situation
• Most of the countries have Nut-a portfolio, focus on this product. Few others focus on Nut-b.
• Focus on packaging format type that has the highest efficiency/line performance to debottleneck the capacity
Table 5. ABC Class Analysis result from 149 FG SKU to be produced by 18%
The Company for the next 12 months
% to annual
Item Class volume Count of SKU % to total SKU
A 70% 26 17%
B 21% 43 29%
C 9% 80 54% 78%
• With harmonized portfolio both on formula and packaging format, the degree of component commonality is increased
• Based on component commonality analysis, the most common components was included into the safety stock
adjustment process based on materials supply vulnerability analysis
• Prolong the materials ordering horizon based on the component commonalities to reduce supplier vulnerability
Regulatory Perspective
5
• Rx (by prescription only)
SKU-a Country-x
Regulatory Complexity
• OTC Drugs 4
• OTC Supplements
3
Prod Dev
1 Criteria:
• Reg Complexity (1-5)
Ramp Up • Vulnerability (1-5)
• Volume (1-10)
0
0 1 2 3 4 5
Production
Vulnerability
18 /// Bay er Indonesia // PQM
Terima Kasih