TakeAway: Distribution is half the battle for marketers. If you can’t get enough of the right product, in the right place, at the right time, you will lose sales regardless of the quality of your product.
Whirlpool took advantage of the recent slowdown to reexamine its distribution system and, as a result, is now enjoying an array of benefits, including $350M+ in savings a year.
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Excerpted from WSJ, “Whirlpool Cleans Up Its Delivery Act,” By Joe Barrett, September 24, 2009
After raw materials, distribution is one of the biggest single costs at Whirlpool, which needs to get bulky products like dishwashers and clothes dryers from factories to customers quickly …
In 2005, the company’s supply chain system was a hodgepodge of warehouses, transport depots and factory-distribution centers. Retailers often had to wait five to 10 days to get new washing machines or other appliances.
Whirlpool undertook a four-year program to build a state-of-the-art distribution system from scratch … The effort is already producing results, allowing Whirlpool to reduce its annual inventory by about $250 million a year and to deliver products in 48 to 72 hours. Whirlpool is also saving costs — about $100 million a year because of improved efficiency …
Whirlpool’s logistics makeover shows how a recession can leave the biggest, best capitalized companies better positioned than ever to scoop up both market share and profits as the economy rebounds …
The company’s ordering and delivery functions used to be located in separate divisions, complicating coordination and resulting in costly mistakes when Whirlpool made too much of a certain product. The distribution system often had to soak up excess inventory …
The core of Whirlpool’s program was replacing 41 outdated sites with 10 huge regional distribution centers that used high-tech warehouse management systems and upgraded vehicles that could handle a variety of products. Now, when trucks deliver appliances from the company’s factories to a distribution center, the merchandise is sorted according to how quickly it is likely to leave. Slower-moving goods, such as certain high-end refrigerators or stoves, are deposited in the center of the building, while fast-moving dryers and washing machines are closer to the loading docks.
The facilities are laid out in quadrants, with most of the products arranged in identical order four times in the same building. That way drivers can access everything they need without going from one end of the building to another …
There are still reduced sales because of the recession, but there are lower than expected inventories thanks to the logistics overhaul …
Edit by TJS
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Full Article
http://online.wsj.com/article/SB125366529324132457.html
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