Analyzing administrative processes in a 3PL company Mapping of administrative processes and identification of key time drivers Master of Science Thesis in the Master Program, Supply Chain Management DAVÍÐ ÞÓR FRITZSON KRÍA SÚSANNA DIETERSDÓTTIR Department of Technology Management and Economics Division of Logistics and Transportation CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden, 2012 Report No. E2012:096 REPORT NO. E2012:096 Analyzing administrative processes in a 3PL company Mapping of administrative processes and identification of key time drivers Master thesis in the Master´s Program Supply Chain Management DAVÍÐ ÞÓR FRITZSON & KRÍA SUSANNA DIETERSDOTTIR Department of Technology Management and Economics CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden 2012 Analyzing administrative processes in a 3PL company Mapping of administrative processes and identification of key time drivers DAVÍÐ. FRITZSON & KRÍA. DIETERSDÓTTIR © DAVID. FRITZSON & KRIA. DIETERSDOTTIR, 2012. Technical report no E2012:096 Department of Technology Management and Economics Chalmers University of Technology SE-412 96 Gothenburg Sweden Telephone: + 46 (0)31-772 1000 Chalmers Reproservice Gothenburg, Sweden 2012 i Abstract As administrative services for 3PL companies can be very specialized and customer unique it can be difficult to estimate and specify the amount of administration needed for a future client. At Schenker Logistics Landvetter this has become one of the most problematic factors when quoting possible clients i.e. to estimate the manning need in the Control Towers (CT), where the majority of administration is performed. Therefore, the main purpose of this thesis is to analyze what drives time in the CT and how much. In order to fulfill this, two main sources of data were needed. Firstly, in order to increase the knowledge on what activities are performed in the CT, all processes for the customers covered in thesis were mapped and described in detail. This was made possible by observing the processes and interviewing the staff responsible for each customer, identifying which processes were executed and from there going through each step of the process in detail. Secondly, a time study was performed by measuring the time duration per process and identifying different time drivers from direct observation, interviews and time templates. These results were then consolidated in to a generalized framework that was used to create an algorithm that is supposed to calculate the basic CT manning need for a future client. This then leads to the discussion part of the thesis where improvement recommendations were suggested both in relation to pricing the CT function in a more precise and accurate way as well as general improvements identified by the CT staff and authors. Keywords: process mapping, administrative processes, time drivers, pricing administrative services ii iii Table of Contents 1 Introduction ..................................................................................................................................... 1 1.1 Background ................................................................................................................... 1 1.2 Problem discussion ........................................................................................................ 2 1.3 Purpose and research objectives .................................................................................... 3 1.4 Delimitations ................................................................................................................. 4 1.5 Thesis outline ................................................................................................................ 4 2 Literature review ............................................................................................................................. 5 2.1 Processes ...................................................................................................................... 5 2.1.1 What is a process? ........................................................................................................... 5 2.1.2 Process mapping .............................................................................................................. 5 2.1.3 How to perform process mapping ................................................................................... 6 2.1.4 Process mapping techniques and icons ........................................................................... 6 2.2 Time studies .................................................................................................................. 8 2.2.1 Time drivers ..................................................................................................................... 9 2.3 Cross training ................................................................................................................ 9 3 Method .......................................................................................................................................... 11 3.1 Research approach ...................................................................................................... 11 3.2 Data collection ............................................................................................................ 12 3.2.1 Interviews and observation ........................................................................................... 12 3.2.2 Time study ..................................................................................................................... 13 3.2.3 Literature review ........................................................................................................... 13 3.2.4 Other source of data ..................................................................................................... 14 3.3 Method assessment ..................................................................................................... 14 4 Empirical data ................................................................................................................................ 15 4.1 Schenker Logistics Sweden (SLOG Sweden) ................................................................... 15 4.1.1 Schenker Logistics Landvetter (SLL) ............................................................................... 15 iv 4.2 Main processes in the CT ............................................................................................. 16 4.2.1 Inbound ......................................................................................................................... 16 4.2.2 Outbound ...................................................................................................................... 16 4.2.3 Returns .......................................................................................................................... 16 4.2.4 Meetings ........................................................................................................................ 17 4.2.5 Invoicing ........................................................................................................................ 17 4.2.6 Support and problem solving ........................................................................................ 17 4.3 Process mapping and descriptions ................................................................................ 18 4.3.1 Customer A .................................................................................................................... 18 4.3.2 Customer B .................................................................................................................... 32 4.3.3 Customer C .................................................................................................................... 49 4.3.4 Customer D .................................................................................................................... 60 4.3.5 Administrative processes in the CT ............................................................................... 75 4.4 Time-study .................................................................................................................. 75 4.4.1 Customer A .................................................................................................................... 76 4.4.2 Customer B .................................................................................................................... 80 4.4.3 Customer C .................................................................................................................... 82 4.4.4 Customer D .................................................................................................................... 84 4.5 Pricing of CT services ................................................................................................... 86 4.5.1 Current pricing approach .............................................................................................. 86 4.5.2 Problem discussion ........................................................................................................ 87 4.5.3 Improvement suggestions ............................................................................................. 87 5 Analysis .......................................................................................................................................... 88 5.1 Most time consuming processes .................................................................................. 88 5.1.1 Customer A .................................................................................................................... 88 5.1.2 Customer B .................................................................................................................... 88 5.1.3 Customer C .................................................................................................................... 89 5.1.4 Customer D .................................................................................................................... 89 5.2 Possible time drivers .................................................................................................... 89 5.2.1 Customer A .................................................................................................................... 89 5.2.2 Customer B .................................................................................................................... 91 v 5.2.3 Customer C .................................................................................................................... 93 5.2.4 Customer D .................................................................................................................... 94 5.3 The algorithm .............................................................................................................. 95 5.3.1 Volumes sheet ............................................................................................................... 97 5.3.2 The calculation sheet ..................................................................................................... 98 5.3.3 Front page ................................................................................................................... 103 5.3.4 Limitations of the algorithm ........................................................................................ 104 6 Discussion and recommendations .............................................................................................. 105 6.1 Pricing of the CT ......................................................................................................... 105 6.2 Getting customers routined ........................................................................................ 107 6.3 Staff cross-training ...................................................................................................... 110 6.4 Communication between CT and production ............................................................... 110 6.5 Improvements in the invoicing process ....................................................................... 110 6.6 Improvements in the return process ........................................................................... 111 7 Conclusions .................................................................................................................................. 112 7.1 Concluding remarks .................................................................................................... 112 7.2 Future studies ............................................................................................................ 113 8 References .................................................................................................................................. 114 Appendix A ............................................................................................................................ 115 Appendix B ............................................................................................................................ 116 vi vii Preface This Master thesis was performed at Chalmers University of Technology as a part of the master program, Supply Chain management. It was done in collaboration with Schenker Logistics Landvetter (SLL) which provided us with a great opportunity to apply our theoretical knowledge to a real life situation. There were many employees at SLL that assisted us during the thesis work and offered us valuable insight into how 3PL companies work today and therefore we would like to show our appreciation to them. Firstly, we would like to thank our two supervisors at SLL; Nikolai Kolderup-Finstad and Milvi Piibeman which offered us a great guidance and support throughout the thesis work. We would also like to thank the amazing people in the control towers at SLL which provided us with explanations and valuable inputs. Furthermore, various other people at SLL offered us guidance and insight into different aspects in the company and thus we would like to express our appreciation to them. Furthermore, we would like to thank our supervisor and examiner, Ola Hultkrantz, for directing us, providing constructive criticism during our research and for assisting us with various issues and questions. Last but not least we would like to thank our families for their support and understanding which they have shown us during this demanding period. viii List of figures FIGURE 1. OUTLINE OF THE THESIS 4 FIGURE 2. TYPICAL FLOWCHART (DAMELIO, 2009) 7 FIGURE 3. CROSS- FUNCTIONAL PROCESS MAP (DAMELIO, 2009) 8 FIGURE 4. RESEARCH APPROACH USED IN THE MASTER THESIS 12 FIGURE 5. SCHENKER LOGISTICS AT LANDVETTER 15 FIGURE 6. THE CT IS A CENTRALIZED PLANNING AND CONTROL DEPARTMENT WITHIN SLL 16 FIGURE 7. INBOUND PLANNING PROCESS 19 FIGURE 8. INBOUND RECEIVING PROCESS 22 FIGURE 9. THE OUTBOUND PROCESS FOR BOOKING CONFIRMATION 24 FIGURE 10. EXPRESS TRANSPORT BOOKING 25 FIGURE 11. RUSH TRANSPORT BOOKING 26 FIGURE 12. EXPORT DOCUMENTATION FOR NON-EU SHIPMENTS 27 FIGURE 13. ALL PROCESSES IDENTIFIED FOR CUSTOMER A 30 FIGURE 14. THE PLANNING PROCESS FOR TRUCK SHIPMENTS 34 FIGURE 15. RECEIVING PROCESS FOR TRUCK SHIPMENTS 36 FIGURE 16. PLANNING PROCESS FOR CONTAINER SHIPMENTS 38 FIGURE 17. RECEIVING PROCESS FOR CONTAINER SHIPMENTS 39 FIGURE 18. OUTBOUND PROCESS- PRIORITY LIST 40 FIGURE 19. OUTBOUND PROCESS- EXPORT DOCUMENTATION FOR NON-EU COUNTRIES 41 FIGURE 20. OUTBOUND PROCESS- CUSTOMS CLEARANCE FOR EU-COUNTRIES 43 FIGURE 21. INVOICING PROCESS- TRANSPORT INVOICE 45 FIGURE 22. INVOICING PROCESS- HANDLING INVOICE 46 FIGURE 23. ALL PROCESSES IDENTIFIED FOR CUSTOMER B 49 FIGURE 24. CONTAINER SHIPMENT PLANNING 51 FIGURE 25. CONTAINER SHIPMENT RECEIVING 52 FIGURE 26. TRUCK SHIPMENT PLANNING 53 FIGURE 27. TRUCK SHIPMENT RECEIVING 54 FIGURE 28. STANDARD TRANSPORT BOOKING 55 FIGURE 29. OUTBOUND- UNLOCK ARTICLES FROM SYSTEM 56 FIGURE 30. INVOICING PROCESS- HANDLING INVOICE 57 FIGURE 31. RETURN SHIPMENT PROCESS 58 FIGURE 32. ALL PROCESSES IDENTIFIED FOR CUSTOMER C 59 FIGURE 33. INBOUND PROCESS 61 FIGURE 34. OUTBOUND PROCESS- ROLL-OUT ORDERS 64 FIGURE 35. OUTBOUND PROCESS- APPROX ORDERS 67 FIGURE 36. INVOICING PROCESS- HANDLING INVOICE 69 FIGURE 37. INVOICING PROCESS- TRANSPORT INVOICE 70 FIGURE 38. ALL PROCESSES IDENTIFIED FOR CUSTOMER D 72 FIGURE 39. GENERAL ADMINISTRATIVE PROCESSES IN THE CT 96 FIGURE 40. VOLUMES SLIDE IN THE ALGORITHM BASED ON THE GENERAL TIME DRIVERS ANALYZED (REAL FIGURES NOT DISPLAYED) 97 FIGURE 41. CALCULATIONS SLIDE IN THE ALGORITHM (REAL FIGURES NOT DISPLAYED) 99 FIGURE 42. THE FRONT PAGE OF THE ALGORITHM - OVERALL CALCULATED MAN NEED FOR A NEW CLIENT CUSTOMER (REAL FIGURES NOT DISPLAYED) 104 file:///C:/Users/gizmo363/Dropbox/Mitt%20drast/Masters%20verkefni/Thesis/Thesis_%20Chalmers.docx%23_Toc343012633 ix List of tables TABLE 1. PROCESS MAP ICONS AND DEFINITION (CONGER 2011, DAMELIO 2009) ............................................... 7 TABLE 2. ALL ADMINISTRATIVE PROCESSES FOR THE FOUR CUSTOMERS ............................................................ 75 TABLE 3. TIME DURATION FOR EACH PROCESS- CUSTOMER A ............................................................................ 80 TABLE 4. TIME DURATION FOR EACH PROCESS- CUSTOMER B ............................................................................. 82 TABLE 5. TIME DURATION FOR EACH PROCESS- CUSTOMER C ............................................................................. 84 TABLE 6. TIME DURATION FOR EACH PROCESS- CUSTOMER D ............................................................................ 86 TABLE 7. DEFINITION OF CUSTOMER SIZE IN REGARDS TO QUANTITY OF IN- AND OUTBOUND ORDERS ......... 101 x List of abbreviations SLOG- Schenker Logistics SLL – Schenker Logistics Landvetter SLA- Schenker Logistics Arendal CT- Control Tower SD- Solution Design POD- Proof of delivery BDM- Business Development List of definitions Administrative process – is basically related to all activities that are needed to control and coordinate the flow of goods and information to and from the warehouse and ensure a smooth and reliable flow. This includes processes such as transport bookings, planning inbound orders as well as providing support to all main stakeholders, especially customers. Bonded warehouse – is an area where goods can be placed in order to postpone the payment of customs fees. Centiro – is SLL´s automatic transportation booking system. Crystal reports- are reports designed by the IT-support that provide the CT with different statistical information on the warehouse operations that are necessary for various CT processes. DB Schenker´s Web-TA – is the web portal for DB Schenker where it is possible to book and track shipments e.g. with Schenker Land. Inventorying- is a verification of quantities kept in the warehouse. KGH- is a company that manages administrative functions in the bonded warehouse which is located within the SLL warehouse for one of SLL´s customers. Learning curve- is a specific time period which it takes both parties (the CT and a new customer) to get to know each other’s work methods, communication ways, getting used to each other user interfaces etc. and thereby reach a standard productivity and man need in the CT. Production – The main part of SLL´s warehouse where all handling operations are performed and goods are stored. SAP- is a system which is e.g. used to approve invoices from transport companies and to create invoices for SLL´s customers. Transportal - is an invoicing system which is used for e.g. transportation invoicing. WMS- is the warehouse management system which is used at SLL. 1 1 Introduction In this chapter an introduction is given to the reader which starts with a background to the issue. This will lead into a problem analysis where the issues facing Schenker Logistics Landvetter are discussed. Furthermore, the purpose, research objectives and thesis limitations will be presented. 1.1 Background In recent years products have in general become more standardized and therefore companies have been forced to come up with new innovative ways to reach customers e.g. in forms of different services (Ford et al, 2003). Consequently, markets are developing towards more service orientation in order to improve their offerings and differentiate themselves from their’ competitors (Christopher, 2011). This as well as emerging technologies has led to a power shift towards the customers (Stroeken, 2000). In relation with these rapidly evolving information technologies the internet plays a vital role in the power shift over to customers (Morris, 2002). This is because the internet provides a more transparent look at the market for customers, enabling them to have a good view over total offerings available (Stroeken, 2000). Therefore, customers are becoming more demanding in regards to quality, prices and services which further increases the difficulties of both keeping clients as well as getting new ones. Furthermore, purchasing decisions are gradually moving away from brand loyalty and thus customers don’t hesitate to switch their commitment to other companies that provide superior services and products at competitive prices (Stapleton et al, 2012). More specifically concerning the 3PL industry, which is the focus of this thesis, you will find the same developing trends in the last few years. Increased competition in the 3PL marketplace as well as more demanding customers (Langley, 2012) has put more pressure on 3PL providers to provide state-of-the-art services while still striving for cost reductions in order to be able to offer as competitive offerings as possible. Moreover, constantly developing information technology systems that e.g. allow companies to offer different kinds of administrative services such as transport administration have become a key tool for 3PL´s in providing innovative and differentiating services to customers. Consequently 3PL´s are able to provide opportunities to link supplier and buyer together and provide real time information on the status of products which enhances visibility and transparency in the material and information flow (Stroeken, 2000). Furthermore, an important feature of the 3PL industry is the very different Customer Base in relation to the characteristics of the offerings needed for each customer as well as industry environments of these customers (Kolderup, 2012). This means that since operating within different types of industries, these customers will have very different needs and expectations and thus require different services. As stated by Lamb (2012) services that 2 many providers offer have great heterogeneity of in- and outputs and thus they tend to be less standardized and uniform. Consequently, it can be hard to define the time duration of each service offered and identify associated costs. Additionally, 3PL provider’s work with customers with different information about their logistics processes, including the administrative work needed (Kolderup, 2012). As a consequence of these various characteristics, 3PL providers will often have problems estimating the administration needed, caused by lack of information on what is needed to fulfill the needs of new clients (Kolderup, 2012). Because of these various issues it can be difficult for 3PL providers to price new services and quote new customers. 1.2 Problem discussion Looking at the case company, the majority of the administrative work is performed in so- called Control Towers (CT). Quoting administrative work in the CT has proven to be very hard since the customer needs for administration can often be difficult to determine. Therefore, it can even be that Schenker Logistics Landvetter (SLL) is performing some administrative services that are not included in agreements with customers. Consequently, customer profitability can turn out to be considerably lower than assumed. This is especially caused by the difficulties in determining the actual administration needed for new customers until they have started working with them and understand what is really needed to fulfill their requirements. This is partly because SLL has customers with different characteristics and within different business environments, such as retail, fashion and industry, each with different needs and knowledge of what is needed. Furthermore, the high degree of specialization and customization of administrative services needed for each customer makes it hard to estimate how much administration is needed for new customers in general. Even for customers working in the same industry there can be differences in requirements they put on their 3PL provider which depends on numerous things. Finally, when quoting new clients, SLL can often have the problem that the customer does not know how much administration is needed to perform the distribution required. This can for instance be that the buying company has had another 3PL provider previously that took care of these services for them and have consequently never had to handle and/or define administration needed for its products. Therefore it is important for SLL to increase knowledge of administrative work performed in the CT for different customers in order to have a better idea of how it will be for a future customer. Furthermore, SLL needs to be able to visualize what drives these administrative hours for different customers in order to identify different time drivers and to ensure quicker, more accurate and transparent quoting of administration for future customers. 3 1.3 Purpose and research objectives As a result of the problem discussion, the main purpose of this thesis is to analyze what drives administrative hours in SLL control tower. Therefore the aim will be to gain deep understanding of all administrative processes of SLL that are executed in the CT in order to be able to describe these processes in detail and identify different time drivers. Additionally, the information will be utilized to provide a calculation tool which will be used to calculate the need for administrative services in the CT. In order to fulfill the aim of the purpose the following research objectives will be addressed: 1. Gain a deep understanding and visualization of administrative processes for SLL. 2. Perform a time study in order to identify different time drivers (what drives time and how much) for administrative processes in SLL. 3. Use information about different time drivers of administrative processes to make a calculation tool for quoting new customers. 4. Identify improvement possibilities in relation to the CT. 5. Examine how administrative services are priced today and how they can be rated in the future. In order to do this, all administrative processes of the customers covered in this thesis will have to be mapped in detail, which will provide an overall picture of the processes. These maps will serve as a framework for how administrative processes look like for different types of customers and make it easier to perform a time study and identify key time drivers of each administrative process. This should enable the researchers to construct a calculation tool that would allow the solution design team (SD) to calculate the cost of administrative services for customers with varying demands and needs and consequently simplify the calculation of the administration work needed when quoting new clients. Additionally the process descriptions and maps can be utilized to realize improvement possibilities to the processes enhancing efficiency and reducing costs. By providing this it is believed that SLL will be able to offer better service to their customers since the company could demonstrate the cost behind the administration needed, provide more accurate estimation of manning need, spend less time on quoting administrative costs for new clients as well as cut unnecessary costs in administration, consequently providing more accurate and better offerings to their customers. 4 1.4 Delimitations The boundaries of the study will encompass the administrative processes which are performed for four selected customers at the CT in SLL and the parts of the company that are directly connected to these processes. In order to have the scope of the study narrow enough to ensure deep description of each customer these four were decided. This was decided in cooperation with the company´s supervisor as well as the manager of the CT since they were considered to be very different, therefore covering much of the work performed in the CT. 1.5 Thesis outline Literature review– In this chapter the theoretical framework from the literature review is presented. It should provide the reader with explanation of the main concepts in the thesis and serve as guidance to how the research was performed. Method– The research study was performed with an inductive approach which is described in chapter 3. Furthermore, the gathering of information, data analysis and working methods are discussed. This is followed by a reflection on the thesis quality, in regards of validity and reliability. Empirical data- In this part of the thesis the focal company, SLL, as well as the CT are presented. This is followed by a general overview of the main processes identified in the CT. Thereafter, each process of the four customers is mapped and described. Finally, it explains how the four customers are priced for the administrative services and time study results are presented (see figure 1). Analysis- In this chapter the empirical findings from the time study and process maps are combined. Firstly, the most time consuming processes for each of the customers are presented which is followed by a discussion of time drivers. These time drivers are then generalized which serves as a basis for an algorithm which should enable SLL to calculate the administration need for future customers. Discussion and recommendation- This chapter contains the main problems and improvement possibilities which were identified by the researchers, CT staff and other employees at SLL. Conclusions- In this final chapter concluding remarks are given which take the thesis aim and objectives into account. This is followed by suggestions for future studies. Figure 1. Outline of the thesis 5 2 Literature review The theoretical framework that was written is intended to guide the reader and introduce and provide explanation on necessary concepts that are used in this thesis. By this the theory is not used in a traditional way to analyze the data gathered but instead provides a theoretical background on important concepts discussed. This should make it easier for the reader to understand how this research was performed and on what theoretical background it is based. 2.1 Processes The following sub-chapter defines processes in general and provides an explanation how process mapping can be performed. 2.1.1 What is a process? According to Keller and Jacka (1999) a process in its simplest form can be described as a combination of inputs, actions and outputs. Ewy and Gmitro (2010) further define a process as a series of actions which need to take place in order for an output to occur. Furthermore, these series of actions that occur serve a purpose, that is, they are designed so that the output satisfies a specific aim or goal or meets customers or stakeholders prerequisites and expectancies. According to Conger (2011) a process is the set of repeated steps or tasks that accomplishes some business function and may or may not be interrelated with other processes. 2.1.2 Process mapping Process management is a crucial factor of the services that companies offer. By mapping processes, relationships between different parts within the organization become clear and it provides employees with an overall picture of its processes (Conger, 2011). By increasing the visibility of work performed, communication and understanding can be improved and it can also provide a common frame of reference for the employees involved in certain work processes (Damelio, 2009). Furthermore, process understanding is vital since companies cannot manage, monitor or improve what they don’t understand and know. Processes are the basis of every functions of an organization and therefore any business improvements involve analyzing and improving processes (Conger, 2011). Consequently, by mapping their processes, 3PL companies enhance understanding of them and provide opportunities to improve them. However, when processes are designed or improved it is essential that the requirements of the customer are understood and fulfilled in the right manner. This can often be quite the challenge in the 3PL industry, since you will often have customers that do not understand their’ needs e.g. concerning administration. When process maps are used to illustrate the current state of work done within a company they show a snapshot of a certain combination of functions and in and outputs that are used by the company to create value for the customer. As a result, the maps assist with documenting the existing path to consumer satisfaction (Damelio, 2009). As stated by Christopher (2011), there can be substantial costs associated with satisfying customer 6 demand, however they are often not fully identified and understood by the organizations. As stated above process mapping can increase the overall understanding of different processes within an organization and thus provide an enhanced overview of costs for different customers and their profitability. This gives companies a better holistic understanding of whether their customers are as profitable as estimated or if there are some additional services performed that reduce the cost effectiveness of that customer. 2.1.3 How to perform process mapping The process mapping strategy suggested by Keller and Jacka (1999) includes the following steps: 1. Establish process boundaries 2. Develop a data gathering plan 3. Interview process participants 4. Generate process maps 5. Analyze and use process maps In regards to process boundaries it should be defined in terms of how the process starts and ends. Furthermore, all inputs and outputs should be listed. In the initial step of the data gathering the data which is needed to create the map is determined as well as the questions that should be asked and which individuals to interview. In the third step those individuals chosen are interviewed. The main purpose of performing an interview is to obtain information and to gain a deep understanding of how the process works. As the maps are developed potential problems and improvement possibilities are identified. When the maps have been generated they are analyzed. Conger (2011) agrees with these 5 steps stated above although suggests that an initial interview with these individuals before the process boundaries are established can set the stage for the project and offer researchers an overview of the processes performed. Furthermore, the author argues that when the process maps have been generated they should be verified by those individuals that were interviewed. This is done to ensure that interviewees agree with the details and substance of the maps. 2.1.4 Process mapping techniques and icons There are many mapping methods which can be used to create a process map such as Definition for Function Modeling (IDEF) and Business Process Execution Language (BPEL) (Conger, 2011). However, the generic method is most often used when mapping processes within a company. In the generic method a flowchart is used to illustrate the sequence of the steps that make up a process (figure 2). 7 Figure 2. Typical flowchart (Damelio, 2009) According to Damelio (2009) the more intelligence built in the chart the more useful and valuable it is. What is meant by intelligence is the use of icons that symbolize what takes place in the process. The icons used in process maps are graphics that illustrate different activities or data (Conger, 2011). Table 1 shows examples of icons that are used in process maps and their definition. Table 1. Process map icons and definition (Conger 2011, Damelio 2009) Icon Definition and use The start icon signifies the event or condition that initiates a process. The stop icon signifies the event or condition that ends a process. A plain, directed arrow depicts process flow, showing the sequence of steps in a process. A process box is used to show a step, or set of steps, in a process. The icon symbolizes digital files or databases. The combination of a diamond and process flow arrows represents a decision or condition which is shown in the diamond. One arrow shows the "yes" logic that occurs when the condition occurs whereas the other arrow shows the "no" logic that occurs when the condition is absent. Start Process Stop Data Store ? No Yes 8 A swim lane diagram, which is the actual process map, has one row or a column (depends on whether the map is vertical or horizontal) for each individual, role, function or organization that interacts with the process (Conger, 2011). Cross- functional process map is a combination of a flowchart, swim lane diagram and process icons which illustrate how work is performed in an organization (figure 3). Furthermore, it shows the steps (2) that create the process, the path (1) that transfer inputs into outputs and which actor performs each step in the process (3) (Damelio, 2009). Figure 3. Cross- functional process map (Damelio, 2009) According to Damelio (2009) a cross-functional map should answer the following questions:  Which steps are required to generate a specific output?  In which order are the steps performed?  Who performs each step?  Which handoffs or interfaces are between different functions?  In what parts of the process do the handoffs occur?  Which inputs are required and outputs produced in each step of the process? 2.2 Time studies Ratnatunga et al (2012) discuss the estimation of time for labor hours in service organizations comparing different theory provided on these issues. There, they discuss that firstly, you need to understand that defining the labor hours in service companies can be much harder because of a much more diverse activities performed by the staff. Also these activities can vary substantially in frequency and time and are often not as standardized as e.g. manufacturing activities. Commonly this is done by estimating the percentages of time spent on different activities. Kaplan and Anderson (2007) do not agree with this definition, since it normally ends up in 100% time, consequently disregarding the idle time that exists in all operations and therefore estimating the theoretical capacity instead of practical capacity. Instead they encourage that the time for performing different activities should be measured/estimated in minutes/hours by direct observations, interviews and comparative information from the cost estimators. This however is argued against by several authors 9 such as Everaert and Bruggeman (2007) stating that observations by cost estimators can result in less correct measurements. Furthermore, Kaplan and Anderson (2007) discuss how the idle time can be estimated. They state a rule of thumb that says that around 15-20% of the overall available time can be considered as idle, i.e. waste. Factors causing this can be maintenance and repair for machines. For employees; walking to the restroom, communicating with fellow staff, arriving and leaving workplace as well as general training are examples of factors that can be considered causing idle time. Then, in relation to the factors mentioned, normally a higher idle time (20%) will be associated with employees than machines (15%). Ratnatunga et al (2012) agree with this in their case study, where the case study company defined the normal capacity as 80% of the theoretical capacity. 2.2.1 Time drivers When performing a time study on specific processes it is necessary to define certain factors that cause time to increase for activities performed in these processes. These are so-called time drivers. Everaert and Bruggeman (2007) define this in their discussion on the time- driven activity based costing method, were time drivers are an important part. There, time drivers are defined as characteristics that affect the time that will be consumed for that specific process or activity. Number of orders, order lines, shipments as well as characteristics such as type of orders, complexity and type of a customer are all examples of time drivers that will affect the time it takes to perform a specific activity. There are many time drivers that influence how much time the CT employees spend on each process. The time drivers considered in this thesis are mainly two dimensional. The number of occasions performing each process is one of the dimensions whereas the other one is factors within the process that drive the time. The time drivers within a process can be manifold. For example, the type of order is one of these factors, as can be seen in the customer descriptions the time spent on each order type can vary substantially. Furthermore, the number of orders within one shipment can influence how long time is spent on the process. 2.3 Cross training Cross- training is used to improve team flexibility and coordination (Levi, 2010). In cross training, members of the team are trained in the technical skills of two or more jobs and thus allowing the team to respond flexibly to changes in the work environment and to employee changes. Furthermore, it enables team members to gain a better understanding of different roles and interconnections in the team which in turn can lead to a shared view of how the team operates and the coordination which is needed in the team (Levi, 2011). According to Daft (2010) there can be many advantages associated with cross training such as it advocates an emphasis on collaboration and teamwork and it promotes a rapid response to changes in the customers’ needs. However, it can limit in- depth knowledge and 10 skill developments since employees have multiple task to focus on. Thus it is important that employees are given the chance to maintain and develop technical expertise (Daft, 2010). 11 3 Method This chapter describes how the study was conducted throughout the thesis. Furthermore, the working methods, gathering of information and data analysis are illustrated. Lastly, the method used will be assessed in regards to the quality of the thesis. 3.1 Research approach According to Bryman and Bell (2011) there are five different types of research designs; experimental, cross- sectional, longitudinal, case study and comparative design. The choice between these five types depends on the purpose of the research. What differentiates a basic case study from these other four research designs is the emphasis on a limited situation or system (Bryman and Bell, 2011). A case study is described by Gilham (2010) as an investigation which enables the researcher to answer defined research questions. By seeking, abstracting and collecting different types of data within the case setting the researcher should get the best possible answers to the research questions. A fundamental characteristic of a case study is that the researcher starts by observing the context before theoretical notation is made. This is done to get an understanding of the research area and thereafter find the theory that is most related to the subject (Gilham, 2010). Since the main aim of this thesis is to gain a deep understanding of the administrative processes performed in the CT within SLL by applying the researchers’ knowledge and theories to the subject, a case study design was chosen. Furthermore, the case study was executed with an inductive approach. According to Bryman and Bell (2011) an inductive research study is a bottom up approach where the researcher makes an observation built on a topic of interest which theory is built on. Related theories are not considered until further along into the research. From this observation clusters of data or patterns begin to emerge which the researcher generates themes that come from the analysis of the data. By going back and forth between the data and the theory enables the researcher to make sense of his data. However, research is rarely entirely inductive since the researcher usually reviews and reads existing theory to be able to start his initial approach to data collection therefore the inductive approach entails a modicum of deduction (Bryman and Bell, 2011). To be able to begin the data collection the researchers started by looking into existing theory. This enabled them to understand how to obtain the data needed and how it could be used. However, to a large extent the existing theories were not considered until the majority of data had been gathered and the analysis was nearly completed. Therefore, the research study was done with an inductive approach with modicum of deduction. The research approach for the thesis can be seen in figure 4. 12 Figure 4. Research approach used in the master thesis 3.2 Data collection Data collection and empirical research is usually divided into three categories; quantitative, qualitative and mixed research (Bryman and Bell, 2011). Gillham (2010) describes quantitative methods as those that include counting and measuring whilst qualitative methods focus mainly on information deducted from interviews and direct observation that enables the researcher to understand the context. Although qualitative data is most often predominant in case studies, quantitative data can enhance the overall study and since all data should be combined in the researcher’s data collection a case study design is most often a mixture of qualitative and quantitative methods (Gillham, 2010). A mixture of both methods was used in the thesis in order to address the research objectives and fulfill the aim of the thesis. Gathering qualitative data through interviews and observation enabled the researchers to gain a deep understanding of the administrative activities performed at the CT and draw process maps as well as gather information on interesting discussion subjects. Thereafter, quantitative data was gathered through studying and measuring both variable and fixed time factors which enabled the researchers to formulate an algorithm. 3.2.1 Interviews and observation In order to gain a broader picture of the activities performed in the CT the researchers begun by having short introduction meeting with all employees of concern in the CT, going through every customers flow in a general way. Thereafter qualitative data was gathered through process observation and semi structured interviews with numerous employees of interest in the CT and other departments within SLL. Bryman and Bell (2011) describe semi structured interviews as approach where the researcher has a list of questions which cover relatively specific topics. However, the researcher has some leeway to ask supplementary questions in response to what is seen as significant to the problem on hand. Therefore the emphasis should be mainly on how the interviewee frames and understands specific issues. By having this flexibility the researcher is able to adjust the emphasis in the research if important topics arise during the interview. Bryman and Bell (2011) also argue that direct observation is an effective method to obtain data needed and it enables the researchers to interact with employees and thoroughly understand the processes. 13 A questionnaire (see appendix B) for the interviews was formulated with the help of the SLL supervisor in order to ensure that intended data was captured. To gain a deeper understanding how each process worked, what drove administrative work and to identify decisions required and documents used for every step of the process, selected people of interest were interviewed. All interviews were audio recorded in order to assure that misunderstandings or interpretations would not occur. After every interview the recordings were played again, transcribed and analyzed. From the empirical data obtained during these interviews process maps were constructed and each process described in detail. Thereafter, a second interview with the employees was conducted in order to validate and finalize the maps. 3.2.2 Time study The time study was performed by observing the activities that the CT employees in question performed. The time for each activity, within predefined processes, was measured by using stopwatches. However, as the time study was half way through the researchers noticed that many of the activities performed, at the CT, were not directly related to any of the processes that had been defined. This was mainly since all support functions had been defined as customer support and many of these functions were not directly related to the customer as such. However, the activities that were considered to be outside the customer support definition are necessary to be able to serve the customer as best as possible and keep the flow of material and information uninterrupted. Therefore, quite some time had to be spent on redefining processes before the time study could be continued. After spending substantial time observing the employees and measuring the time for activities it was clear that the researcher would not be able to observe and measure the time duration for all processes since some of the processes occur seldom. Therefore, the data needed to be obtained by other means. For those processes that the employees could define the process duration the data was gained by interviewing the employees and thoroughly defining time for each activity within the process. However, in some cases the employees were not able to determine the process duration because they varied substantially in both content and duration between days. Therefore, the data was obtained by having the employees fill out a time template for the process during a specific time period. When data for all processes had been obtained the employees were asked to verify that the average times defined for each process were accurate. 3.2.3 Literature review Theoretical data was gathered by reading books and articles from online databases, such as the Chalmers library database, Emerald and Google Scholar. In order to find books and articles on the databases that were relevant to the thesis work, keywords such as; process mapping, administrative processes and third party logistics, were used. 14 3.2.4 Other source of data Empirical data used in the company description (chapter 4.1) was collected through the company homepage as well as through interviews with the SLL supervisor and CT manager. 3.3 Method assessment The fact that time study data was obtained by various means, that is, through interviews, direct observation and time templates could affect the validity of the study. However, it is assumed that since the employees work with these processes from day to day the validity of the data gained from them was similar to the ones that had been obtained through direct observation. Additionally, since the employees verified that the average times established for each process were correct it further increased the validity of the study. Furthermore, since the interviews and time study were conducted on English and the employees in question are Swedish it could be that the researchers were not able to obtain all information needed or some of the information was misunderstood. This could affect the validity of the study. However, since both parties were fully aware of this and the CT employees discussed and clarified points which were in question it is assumed that the validity of the thesis is not affected greatly. Furthermore, as the CT employees were asked to verify that the information obtained was correct afterwards it should further increase the validity. As the interviews were semi structured it could be that the information obtained was diverse between different employees interviewed which could also affect the validity of the thesis. This is mainly since in most instances interviews took different direction depending on the employee in question. However, when the researchers had conducted all interviews and discrepancies were uncovered, additional questions were asked to even out the inconsistencies. According to Bryman and Bell (2011) a reliability of a study is concerned whether its results can be repeated. By using the interview template which was constructed for the employees it is assumed that the study could be repeated. Furthermore, since the time study is described in detail the reliability of the study further increased. However, as the interviews were semi structured there were some topics discussed which were not in the template. 15 4 Empirical data In this chapter the focal company (SLL), Schenker Logistics (SLOG) as well as the control tower within SLL will be presented. Furthermore, general processes are explained and support and problem solving function is described in detail. This will be followed by descriptions and maps of all administrative processes identified in the CT for the four customers, time study results and a description of how the four customers are priced today for the administrative services. 4.1 Schenker Logistics Sweden (SLOG Sweden) SLOG Sweden is a daughter company of Schenker North, which consists of Sweden, Norway, Denmark and England. It is a pure third party logistics company which mainly focuses on warehouse handling. However, the company also buys and sells transport services in collaboration with many different companies (e.g. DHL, Schenker land and UPS) and thus is able to offer complete logistics solutions (Kolderup, 2012). SLOG Sweden has logistics centers at 5 strategic situated locations in Sweden (Jönköping, Skåne, Nässjö, Stockholm and Gothenburg) and total warehousing space of 130.000 m² at their disposal. Furthermore, it has approximately 400 employees and in 2011 the turnover was more than SEK 500 million. The company has around 60 customers in Sweden however, most numbers of customers are located in the warehouse in Stockholm and there is also where they have most of their administrative services (DB Schenker 2012). 4.1.1 Schenker Logistics Landvetter (SLL) In November 2011 SLL moved into a new warehouse located close to the airport in Landvetter Gothenburg (figure 5). After an expansion which is assumed to be finished in the end of 2012 the total floor area will be 40.000 m² with additional 8.000 m² on a mezzanine. At the moment there are eleven customers managed in the warehouse. However, after the expansion the total number of customers will be 12 (Kolderup, 2012). These customers are quite diverse in regards of business characteristics and environment (e.g. industry, fashion) thus they have different needs in relation to warehouse and administrative solutions. Figure 5. Schenker Logistics at Landvetter 16 4.1.1.1 Control Tower The CT is a centralized planning and control department within SLL which enables an effective flow of information and coordination between different entities within the chain (figure 6). Furthermore, the department is responsible for executing main administrative services (e.g. tracking, transport booking and customs handling) for SLL´s customers. A large part of this concerns customer service or support, addressing various issues that occur, in order to ensure an efficient material and information flow. At the moment there are 8 employees in total working in the CT, seven of those being process owners and a CT manager which is responsible for leading and guiding the CT team. Figure 6. The CT is a centralized planning and control department within SLL 4.2 Main processes in the CT Before going in to the mapping of all processes it is needed to provide short explanation on the main processes that are executed in the CT. Furthermore, as the support function is not defined in the same way as other processes, this will be described in more detail. 4.2.1 Inbound The inbound process in the CT is generally split in two phases, a planning phase and receiving phase. Then the activities performed in the CT will be different whether it is a container or a truck that is coming in. These are merely connected to notifying production on an incoming shipment both before and at arrival but as well solving problems that occur. 4.2.2 Outbound The outbound process is mainly associated with two main activities. Firstly, various types of transport bookings are performed by the CT depending on the requirements of each customer. Then for outgoing shipments that are going to a non-EU country, the CT is normally involved in providing the corresponding export documents before the shipment leaves SLL. 4.2.3 Returns For goods that need to be returned from the Customer Back to SLL, for various reason such as wrong pickings, the CT is often enquired to book the transport for this. 17 4.2.4 Meetings The CT along with other SLL staff normally has meetings with the customer a couple of time per month, where the most important issues at that time are discussed. 4.2.5 Invoicing The CT is also mainly responsible for creating the invoices for customers. This can be divided in handling invoicing and transport invoicing. However, the transport invoicing is solely performed for the customers where SLL is responsible for the transport. This process is normally performed once per month. 4.2.6 Support and problem solving As described in the method chapter, the support and problem solving function does not fall under any of the processes defined. Basically these are the activities that are not happening repetitively and can therefore not be related directly to a specific process that is characterized with defined activities and begins with a defined input and ends with specific output. These, were then placed under the same definition; support and problem solving, which was believed to cover the activities performed outside of the defined processes. The support function is divided into four different categories depending mainly on from where the input is as well as the type of support that is performed. Together these factors describe the perhaps most important function of the CT that involves providing support to main processes and thereby ensuring efficient and smooth flow of goods and information from the point of inbound order entry until the goods arrive at the final destination. 4.2.6.1 Customer support Customer support mainly concerns the CT being present for the customer, answering all kinds of questions and enquiries. These can be questions concerning status of orders, inventory status as well as pointers on faults performed by SLL such as wrong labeling. Here the input is normally from the customer´s side. This can often be a quite time consuming function since the CT employee might need to deal with the same issue several times over a specific period of time. This is primarily because the CT employee will receive a question, look into it and provide with an answer, but often the customer wants a “better” answer or looks more closely into it and comes back with a new question. This also makes it quite hard to define customer support as a certain process with a specific input and output since one request can stretch over days, even weeks. 4.2.6.2 Internal support This involves all kinds of internal communication that the CT has with e.g. production, IT support, and economics department and are necessary to ensure a smooth flow of information within the company. Here the input can be both from the CT as well as internal parties. For this process, the CT can spend substantial time with production, walking back and forth in production, discussing different problems that occur and finding solutions. 18 4.2.6.3 External support External support is defined as all support that is offered to external parties other than the customer (e.g. transport companies, KGH). 4.2.6.4 Proactive support Finally, proactive support means that the CT employee has the initiative on identifying issues needed to solve, such as problems with orders and either finding solutions to these, or contacting the right party needed to solve this. This is mainly performed to ensure that the flow of both information and materials is continuous. Finally, these four factors can of course intersect and be interrelated. For example when working on an enquiry for the customer the CT staff will most likely need to communicate with the production staff in order to get correct information or discuss how this can be solved. 4.3 Process mapping and descriptions This sub-chapter focuses on describing both visually as textually all different processes that are performed for each of these four customers in the Control Towers. However, for some of the processes, a process map does not contribute to a better understanding or explanation of the process and is better explained in a text description. Furthermore, improvement possibilities recognized by the CT employees are illuminated. 4.3.1 Customer A Customer A is one of SLL´s newest customers, started in 2011 and is SLL´s second biggest customer in relation to turnover; with for example around 20 blue collar staff in the warehouse. Customer A produces all kinds of working clothes for numerous different industries such as heavy work wear, healthcare, hotels, restaurants, catering and more. Customer A has 250 suppliers that require a lot of work for the unloading of inbound shipments, repacking them and putting away to the shelves. This also means that number of articles is very high. As a consequence of Customer A´s characteristics, there is very much pick and pack performed for them and they have around 50 customers that are sorted into three different zones on the mezzanine in SLL in order to make the pick tour for the pickers shorter and more efficient. 4.3.1.1 Inbound The inbound process for Customer A in the CT can be divided in two separate parts; the inbound planning process and the inbound receiving process. Inbound planning Concerning planning inbound orders, SLL requires that their customers send delivery notifications in advance since it gives them an opportunity to schedule their staffing capacity and to ensure that all inbound orders can be admitted in a quick and efficient manner. Consequently, the inbound process is initiated when the CT receives a delivery notification which today is normally coming from the transportation companies via email. The email 19 contains general information regarding the shipment such as; arrival date, number of pallets, order number and number of packages. The amount of information can however differ substantially and can for example contain only the number of pallets. When the CT receives the notification they normally email Customer A to make sure there is an inbound order for it and then notify production that the shipment is coming in. If there is no inbound order number on the notification the CT will request that Customer A makes sure that an inbound order has been entered in to the system. This is because SLL is not able to enter articles into the system until an inbound order exists for it in the system and Customer A has had some problems with entering all inbound orders in to the system prior the arrival. Normally there should also be an arrival date on the delivery notification stating which date they will deliver the shipment. However there is no specific time slot dedicated for each delivery and the only restriction is that it is not possible to arrive with a shipment later than 16:00 each day since it is too close to closing hours (17.00). Therefore the trucks arrive on any given time between the morning and 16:00 or even the day before or after scheduled arrival day. Before sending a request regarding the inbound order to Customer A, the CT notifies production about the inbound order and writes it on the notification board in the CT. This is done to ensure that everyone knows what is coming in the upcoming hours/days. If an answer is received from Customer A concerning the specific inbound order the CT forwards it to production, otherwise the shipment will arrive anyway. Inbound. Planning process CTCustomer A Production In b o u n d . P la n n in g p ro ce ss Start Send delivery notification Notification received Notify Customer A (3) Mail received Write on board (1) Notify (2) Notification received Stop Detailed description 1. Dates of planned inbound orders are written on a notification board 2. Production is notified that a shipment is expected so that resources can be planned for upcoming days 3. Email is sent to Customer A on information that was received in order to make sure that they have entered and inbound order in to the system before the shipment arrives at SLL. Figure 7. Inbound planning process 20 Inbound receiving As there have been problems with Customer A placing in inbound orders there have been the same difficulties with getting them to send the delivery notifications as requested. This comes to the later part of the inbound process, where the truck arrives at production with the shipment. The process is initiated when the chauffer reports to the CT. The CT employee checks the notification board to see if the shipment has been advised. If not, the CT contacts production and checks if they are able to take it in. This depends on how busy production is at that time and how big the shipment is. If they are not able to receive it, the driver gets a new appointment the latest 24 hours later. However in most cases SLL tries to avoid this because of obvious inefficiencies and extra costs. Also, the CT employee logs this information in to excel that is used to inform Customer A on how many times the CT is not receiving a delivery notification. If the shipment is on the notification board, the CT sends the chauffer to the correct gate number. When arriving at the specific gate the chauffer hands over the shipment documents (waybill, purchasing order, etc.), production counts the number of colli´s (cartons, pallets, etc.) and if correct, confirms that it’s the same amount as on the shipment document. After this, production types the order number from the shipment document into the WMS system to see if it is there. If production is not able to find the inbound order for this shipment, they place it on the warehouse floor and contact the CT asking them to solve this. Furthermore, it is happening occasionally that no order number or other information is on the shipment. This will require quite a lot of extra time for production, the CT and Customer A in trying to investigate what it is that was sent, from what supplier it came from, etc. so Customer A can either locate the corresponding inbound order in their system or create a new one, which then enables them to enter it in to SLL´s WMS. As it is today, production log the shipments with missing inbound orders in to an excel sheet with information given with the shipment, and forward the sheet to the CT around ones a day, both in order to require Customer A to enter these in to the system but as well to monitor if this is increasing or decreasing between weeks/months. When receiving the list, the CT employee forwards it to Customer A and asks them to fix the problem, either by placing an inbound order into the WMS via EDI or if it already exists, forward the order number to the CT so it can be identified. Finally when a reply has been received, the CT employee needs to look in to the system to make sure that all orders have been fixed before forwarding the notification to production. As can be seen, inbound orders are causing quite much problems for all parties involved since it can often be hard for Customer A to realize which order CT´s enquiry concerns and what articles to make an inbound order on. Consequently, it can take even a few days for them to respond to these requests from the CT, especially those that have no inbound orders or lack general information needed. When the orders have been received in SLL´s WMS system via EDI, production can start entering the articles in to the system. First the system will show an unloading list stating exactly what is supposed to have arrived in that order. Production prints the list and counts 21 the cartons to see if the pieces in each carton match with how many they are supposed to be. When finished counting production prints out a label containing barcode and article number as well as information on exactly where to place each carton. This label is placed on each carton. When he has counted everything he reports the exact numbers into the system. This usually varies, especially in textile since suppliers are allowed to round up to their batch sizes to the ordered quantity +/-10%. However always when a mismatch is between the order quantity and shipment quantity, the CT is notified, which then forward this information over to Customer A. Finally, the cartons can be placed in the shelves. Additionally, when registering the shipment into the system there can be some problems occurring that hinder it to be placed in the shelves and entered into the system right away. An example can be that one of the article numbers doesn’t exist in the system. If this occurs, production needs to contact the CT which forwards the problem to Customer A and asks for the information needed to register the article into the system. When the information needed is received from Customer A the CT employee forwards it to the IT support which registers the information into the WMS system. When this is done the shipment can be finalized and placed in the shelves. 22 Inbound. Recieve process CTCustomer A Production In b o u n d . R ec ie ve p ro ce ss Detailed description 1. If production can´t take the shipment in they chauffeur is assigned a new appointment 2. The production employee/s unload the truck 3. An excel file stating all inbound order that are not found in the system is sent to the CT 4. The CT notifies Customer A of all inbound orders that are not found in the system and requests for correction 5. Customer A places inbound orders in system 6. CT checks if everything is okay. Chauffeur reports to CT Start Notification on board ? Assign new appointment (1) Notify chauffeur Unload (2) Order found in system ? Notify (3)Send a request (4) Stop Receive request Reply (5) Place in shelfs and log into WMS Yes Log into excel Can production take it in ? No Yes No No Yes Check in system (6) Log into excel Figure 8. Inbound receiving process 4.3.1.2 Outbound This chapter covers the main processes performed for Customer A´s outbound shipments. Booking confirmations First of all, Customer A manages their transportation through other transportation companies’. The majority of these transports are booked or confirmed automatically through Centiro when production has closed the shipment in the system. Consequently, CT normally has nothing to do with this. One example of this automatic confirmation is the 23 transport company Posten that comes each day of the week to pick up shipments. There, the booking of the transport has already been done but Centiro sends an EDI-file specifying the quantities, article numbers, etc. so Posten can scan the packages in to their system. Another transport company booked automatically is e.g. UPS standard. However, there are two conditions where the CT needs to take part of this. Firstly this is for shipments going with the transport company Dachser. There, e.g. for shipments going to SAS Denmark and SAS Sweden, Posten normally do the transport. However, if these shipments are so called bulk shipments (over 12 packages or a whole pallet) the transport company Dachser is used to do the transportation, which then needs to be manually booked by SLL. This goes for all other shipments going with Dachser. This process is initiated by production seeing that a shipment needs to go with Dachser. Then the booking is sent manually by EDI-file to Dachser. Production then sends the same information to the CT by email and asks them to do a so called security booking with Dachser. This e-mail is then forwarded by the CT employee to Dachser. The reason for this security booking is that there is an issue that has come up sometimes that Dachser only receives the email but not the EDI file from production. In that case, Dachser informs the CT about it which looks in the system to see if it has been sent. If not, the CT employee contacts production and asks them to send the file. Secondly, for shipments going to customers in Finland, Customer A requires that SLL uses the transport company Itella which comes daily to pick up shipments. Consequently, production sends the CT an e-mail each day regarding the freight quantity that needs to go with Itella that day. Thereafter, the CT sends an email (before noon) to Itella stating the amount that will be transported with them. Subsequently, Itella sends the CT the waybill which is printed out and sent to production. 24 Outbound. Booking confirmation CTForwarder Production O u tb o u n d . B o o ki n g co n fi rm in g Detailed description 1. Production sends a booking confirmation request to the CT, containing outbound quantity 2. Booking confirmation sent via email to the forwarder. Request for transport booking (1) Start Waybill sent to CT? Receive request Confirm booking (2) Receive confirmation Receive waybill Forward waybill Waybill received Truck arrives Stop Yes No Figure 9. The outbound process for booking confirmation Express transportation When Customer A makes an outbound order they state if it is an express order. Once production has picked it, it is either brought to the CT or production emails the CT that it has been picked. The CT personnel logs into the system to find shipment information (weight, address, etc.) which is used to fill in the transport booking on the UPS website. Once the transport has been booked the personnel receives an address label. Then, usually the CT employee runs out to production with the address label or the package. Moreover, there are non-frequent customers in Iceland and SAS China that the CT needs to book the transport for every now and then since they are required to be booked with UPS express. This is executed in the exactly same way as the express transportation process since it is with the same transportation company. However these shipments are not “express” shipments as others that are booked with UPS express and therefore do not require the same priority. 25 Outbound: Express transportation Customer A CT Production O u tb o u n d : E xp re ss t ra n sp o rt at io n Send outbound order/request express transportation Start Detailed description 1. Information obtained on the previous step used to fill in transport booking on the UPS website Receive order Pick order Request booking for express transportation Receive request Book transportatiom (1) Receive address label Forward address label Receive address label Load truck Stop Log into system to obtain shipment information Forward order+ tracking number Receive order+tracking number Figure 10. Express transport booking Rush transportation When Customer A needs a shipment to be transported within a very specific time limit such as a few hours, the company requests for a rush or BUD transportation. The main difference between this and a normal express transportation order is that the express order normally just needs to leave SLL the same day, while for rush transport; the shipment needs to be at the customer within one day, even within few hours. The process is initiated when Customer A contacts the CT and informs them that a specific shipment needs to be sent urgently. The CT then contacts production in order to verify that the shipment can be picked within a specific timeframe. As soon as the order has been picked, production either brings it to the CT or sends an email with information regarding 26 weight and amount of packages on the shipment. Subsequently, the CT calls different transportation companies to check for prices and see if the shipment can be delivered within that specific time frame. In some instances Customer A requests to be contacted before the transportation is booked to get the price. If Customer A accepts the prices the transportation is booked otherwise it is booked with express delivery. If Customer A does not ask for the price the CT books the transportation straight away. When it has been booked it is logged it into a excel file and all emails from Customer A regarding that specific shipment are saved as a precaution. Thereafter the shipment is picked up either from the CT or from production. Outbound. Rush transportation CTKwintet Production O u tb o u n d . R u sh t ra n sp o rt at io n Detailed description 1. Order is either brought to the CT or email is sent with information on weight and quantity 2. The CT calls different transport companies to check for prices 3. Booking logged into a excel file for next month invoicing 4. Until the order has been picked up by the transport company it is monitored by the CT employee. Start Request Rush Receive Rush request Request to pick order Pick order Inform CT (1) Receive information Search for best price on Rush (2) Notify Kwintet about price? Agree on Rush price ? Book Rush transport Logg into excel (3) Monitor shipment (4) Shipment picked up Ask for express transportation Book express transportation Yes No YesNo Stop Figure 11. Rush transport booking 27 Export documentation When shipments need to be transported outside of EU (Iceland, Norway, etc.) the CT has to contact Customer A in order to get export documents. The export documents for these shipments are always created at the departure date when the shipment has been picked. The process is initiated when production sends the CT an email regarding non EU shipments with information about the weight and the “order picking numbers”. Before Customer A is contacted the CT goes into the system to obtain the Customer A order number. A request for export documents is then sent to Customer A with all order numbers. Once Customer A has sent the export documentation the CT personnel makes few copies of it and forwards them to production. For shipments going to either SAS Norway (always leave on Mondays) and to Laksevågen (always leave on Tuesdays), this process is always performed once per week. Other non-EU shipments can be leaving at any given time and thus do not have fixed frequency. Outbound. Export documentation Customer A CT Production O u tb o u n d E xp o rt d o cu m en ta ti o n Send email regarding non-EU shipments (1) Start Receive email Log into system (2) Send email with shipment information (3) Receive email Prepare export documentation Send documentation Receive email Make copy´s of documentation Forward documentation Receive documentation Stop Detailed description 1. An email is sent that contains information on weight and the order number of the non-EU shipment 2. A CT employee logs into the system to obtain the Customer A order number 3. A request for export documents is sent to Customer A with both order numbers Figure 12. Export documentation for non-EU shipments 28 4.3.1.3 Return shipments The CT is rarely notified when orders are picked incorrectly and returned. In most cases the information goes straight to production/stock manager. Although when the CT is notified via Customer A the information is forwarded to production which investigates the problem. Production then notifies the CT if the problem has been solved and the information is forwarded to Customer A. 4.3.1.4 Support and problem solving As discussed in the time study chapter (4.4.1), this function is a very large part of the Customer A flow in the CT. This can be related to the fact that Customer A is a fairly new customer at SLL and consequently there have been some problems with them following the requirements set by SLL which has caused delays and inefficiencies in the flow. The support and problem solving for Customer A is split in four parts as defined for all customers. A large part of the support function is directed at answering and finding solutions to customer enquiries. However, quite much time is spent in communication with internal parties such as IT-support and especially production staff and stock manager. Then transport companies can have enquiries concerning several issues that are directed to the CT. Finally, normally when time allows, the CT employee works proactively with solving issues that might cause instability and delay in the flow. Customer support The customers support regards all types of questions and enquiries from Customer A that can arise at any given time. Concerning inbound this can be question regarding why an inbound order has not been entered in to the system. Another request could be concerning if the supplier has only sent part of a specific order and Customer A wants to check if they have received the rest, and if so, when they will be able count and enter it into the system. Concerning outbound, it can be questions such as; what is the tracking number of a specific shipment, why a shipment hasn’t arrived at the customer and when it will arrive, if they sent the right quantity of the right order, etc. Other enquiries can be that Customer A has a request for inventorying (stocktaking). Since Customer A pays an extra fee for this, the CT employee is required to notify its contact person at Customer A to get his approval before doing this. Furthermore, when inventorying is completed, the CT employee needs to take a copy of it, in order be able to show for it, if Customer A would have any comments on it when the invoice is sent each month. Inventorying is normally requested when there are some discrepancies in number of articles between Customer A and SLL. This can e.g. be that Customer A is charged for X number of articles by their supplier but SLL is not putting away the same amount. This can be because the supplier has labeled the packages wrongly causing SLL to enter wrong amount of articles in to the system. 29 Moreover, Customer A might request an order to be deleted (inbound or outbound). Finally, Customer A can have various “pointers” regarding mistakes such as badly packed pallets, wrongly labeled etc. Internal support This function is related to activities that are performed in cooperation with internal parties. For Customer A these are; IT-support, production staff and stock manager. Firstly, concerning IT-support this is mainly if orders get stuck in the system. If identified by IT- support, they contact the CT and let them known what is causing the failure. Then the CT employee needs to contact Customer A and ask them to fix this. This can for example be when an inbound order entered in to the system has an article number that has not been created in the system. For production and stock manager, this is merely related to order problems such as when an inbound order has not been entered into the system at shipment arrival. External support This function is the least time consuming for the CT employee in Customer A´s case and is mostly associated with giving answers to transport companies on various questions regarding the transport (e.g. address). However, since Customer A is responsible for the transport, they are responsible for most activities after the truck has left SLL (e.g. tracking shipments). The CT employee is also contacted by companies that transport for SLL (e.g. UPS, Schenker Land). There can be various issues or questions that the companies bring up and in some cases the employee needs to contact production to be able to answer. Proactive support When time is available, the CT employee spends time on looking through problems that are on standby and sees if it is possible to find solutions to these, first by looking at it themselves, finding the source of the problem, and if they are not able to solve it, contact the correct person to do it. Furthermore, the CT employee looks through the system, discusses with production, etc. in order to make sure that everything is running smoothly. If problems are identified, the CT employee contacts the person that is able to solve this. Finally this can also be all kind of information that CT provides to Customer A in order to avoid misunderstandings. This can for example be if WMS sends wrong information to Customer A regarding stock status, inbound orders, outbound shipments, etc. As can be seen from the description of this support function, the time that is consumed in the CT depends on how much is to do for the CT at each time. Therefore if less time is spent with the general processes; more time can be spent answering customer support questions, discussing with production and proactively supporting the customer in order to ensure that the whole flow is working. 30 4.3.1.5 Telephone meeting Every other week a telephone meeting with representatives from Customer A is held. During the meeting recent or previous issues in e.g. inbound or outbound are discussed and improvement possibilities suggested. Also some general information updates are given by both parties. Then it depends a lot on the subject of each meeting how much the CT employee needs to do after the meeting, such as emailing different information or documenting new routines. 4.3.1.6 Invoicing Since Customer A is a relatively new customer the CT is only involved to a small extent in the invoicing. For the main part it is done by the Customer A project manager. In the end of every month the CT personnel collects all rush invoices and logs it into a excel file including the activities which have been performed that are not included in the contract. These are quite many today because of the problems that have been in this flow, e.g. for not entering inbound orders in to the system. The excel sheet is then sent to the project manager. 4.3.1.7 Overview of processes Figure 13 provides an overview of all process defined for Customer A. Figure 13. All processes identified for Customer A 4.3.1.8 Improvement suggestions by employees In this chapter improvement possibilities recognized by the CT employee are illuminated. Inbound Like can be seen from the description of the process, there are many problems with the inbound process today, partly caused by Customer A, which can be hard for SLL to control or 31 resolve. One reason for this is that the requirements for sending delivery notifications and inbound orders have not become a standard routine for Customer A. The CT employee believes that this can for example be because there are many different parties responsible for notifying SLL for different shipments such as suppliers, transport companies as well as Customer A itself. Consequently, this process is taking substantial time for the CT, communicating with production and Customer A back and forth as well going into production discussing with them in order to understand the problems more thoroughly. In order to fix this SLL could simply not allow Customer A to send any shipments before they have put in an inbound order. As easy as it sounds it can however be challenging to implement in a real life situation but should benefit both parties if implemented successfully. Another way could be to put a limit on how many shipments can be taken in without a notification. Additionally, inbound trucks are not being given a time slot per day, but can be arriving at any given time which makes it harder for production to schedule their capacity. This should be changed so SLL would tell the transport companies when they could deliver the shipment. However it also needs to be considered that Customer A is a relatively new customer and it can take some time to get the requirements that SLL puts on its customers in to a routine. During the first interview there had already been made some improvements regarding these issues and a month later when the observations were made it was clear that these matters have improved quite a lot. Firstly, Customer A has improved the number of inbound orders sent to SLL pre delivery. This is a result of frequent meetings between SLL and Customer A, where CT has pushed this. Also the CT has worked continuously on letting Customer A know each time they get a notification so Customer A can make sure that an inbound order has been placed. Secondly, Customer A has improved sending delivery notifications and is now mainly having their transport companies sending delivery notifications instead of three different parties. From this it can be assumed that this will continue to improve and the requirements that SLL puts on Customer A will hopefully have become a standard routine for Customer A in several months’ time. Finally there are improvement possibilities within SLL as well which mostly seem to be connected to better communication between production and the CT which would make the coordination of information between Customer A, the CT and production a lot easier and more efficient. Meetings A routine internal meeting with those that are involved in the functions connected to Customer A could possibly improve procedures as well as the information flow between different departments. Invoicing Since the CT has to invoice Customer A for every activity performed which is not stated in the contract they have to know exactly what is included in it. In order to make certain that 32 Customer A is invoiced for all additional functions the CT should have a clear listing of what is included in the contract. However some responsibility must also be put on the CT, to really try to understand what is included and what´s not and charge for everything that is not. Some segments in the contract also have to be updated, since some procedures have changed considerably as well as the proportion between different procedures. Return shipments Since the CT is rarely notified about orders that have been incorrectly picked it is hard for them to see if there is any correlation between occasions and find improvement possibilities. If a standard procedure would be established it could lead to improvements in this sector. Reoccurring problems could possibly be eliminated which would lead to both parties gaining. Also CT/SLL wants to be able to keep log on the wrongly picked articles to compare to the contracts. However this is a problem at the moment since Customer A is not able to provide this information currently. Support and problem solving The support function is a very big part of the Customer A flow. Because of the instability in this flow, Customer A has frequent enquiries many of which concern inbound orders. As discussed before this can be traced back to lack of organization at Customer A that result in faults. Furthermore, Customer A is a fairly new customer as well as a very big one which makes mistakes more frequent. It is believed that when they have settled better and routines have been defined more clearly, both at SLL as well as Customer A, the support function should not be as time consuming as today. However, in order for this to be possible some improvements need to be made. First, it needs to be demonstrated in very clear way why it is important for Customer A to set clearly defined routines for sending a delivery notification, entering inbound orders in to SLL´s system before arrival of shipment, etc. When this has been achieved Customer A will be forced to make changes in order to fix this, which could for example be done by having fewer persons responsible for these actions or even having a coordinator that would be responsible for the flow, making sure that nothing goes wrong. However, Customer A is a large and complex customer with goods coming from different places which make it harder to execute this. 4.3.2 Customer B Customer B is a company that purchase and distributes fashion apparel such as Lacoste and Caterpillar in various countries in Europe and is one of the strongest in this area in the Nordics and Baltics. Customer B has been a customer at SLL for around five years. In relation to turnover; number of staff in SLL, inbound and outbound orders, etc. Customer B can be considered as a mid-size customer. Around 70% of their goods that go through SLL are repacked and sent from the warehouse within a short period. This means that there is quite 33 a lot of handling such as pick and pack performed for the customer. Additionally, as a fashion apparel distributor, there are considerable seasonal variations in volumes handled. 4.3.2.1 Inbound For the inbound procedure at CT there are mainly two inputs depending on if it is a container or a truck shipment that is coming in. Then the truck shipment can be divided in to two separated phases, the planning phase and the receiving phase. In the planning phase there are two possible inputs; if the transportation is booked by Customer B or if the CT books the inbound transport. In the receiving phase there are also two possible inputs; if delivery notification was sent prior to the truck arriving versus if no notification was sent before the truck arrives at SLL. Truck shipments planning In some cases the CT employee books inbound transportation (shipments coming from Netherlands, Spain or Portugal). When the CT gets a booking request from Customer B an email is sent to the booking office at Schenker Land in Gothenburg. Usually Customer B is notified that the transport has been booked. When a delivery notification has been received from Schenker Land the CT employee writes the planned delivery on the notification board. The CT employee also gets a tracking number from Schenker and tracks the shipment until it arrives at SLL. When Customer B handles the transport booking the process is initiated when the CT receives a notification from the transport company. The CT is usually notified by the transport company at least one day before the shipment arrives. Thereafter, the CT employee writes the planned delivery on the notification board, prints out a packing list from Customer B and hands both the list and the delivery notification over to production. This is done so that production can plan how many employees from the staffing agency Uniflex will be needed the coming day. 34 Inbound.Truck shipment planning CTCustomer B Production In b o u n d .T ru ck s h ip m en t p la n n in g Start Transport booking performd by Customer B?(1) Receive delivery notification Send request Receive request Book transport (2) Send notification (3) Receive notification Write on notification board Print out packing list Notify production (4) Receive documents Plan staff Stop Detailed description 1. If Customer B or their suppliers book the inbound transportation the process is initiated when the CT receives notification from the transport company. However when the CT books the transport the input is a booking request sent by Customer B.. 2. An email is sent to the booking office of Schenker in Gothenburg. When the booking is done the CT employee receives a tracking number and the shipment is monitored until it arrives at SLL. 3. As soon as the booking is completed a notification is sent to Customer B. 4. The CT employee notifies production b