n the context of the Case above, what are the critical factors,  that have contributed to the successful implementation of VMI system and the consequent reduction in Inventory holding in MSIL?

Practical Management Science
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ISBN:9781337406659
Author:WINSTON, Wayne L.
Publisher:WINSTON, Wayne L.
Chapter2: Introduction To Spreadsheet Modeling
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Maruti Suzuki India Limited (MSIL) – Vendor Managed Inventory (VMI)Maruti’s approach to Vendor Managed Inventory (VMI) system is through strategic partnership with it’s vendors. It supports collaborative planning, mandated cost and activity transfer to the suppliers, and automated replenishment. Collaborative planning and related information sharing with vendors are the prerequisites of VMI as in their absence, the supplier cannot have the visibility of production plan and therefore, cannot be expected to maintain and manage inventory in a blind situation of planning. Vendors are mandated to own the activity and costs related to management of inventory even at the buyer (MSIL) site. Automated replenishment system is the final objective of any VMI system, in which the execution against the replenishment strategy is done automatically through an IT- enabled system on the basis of daily changes in inventory and demand at the replenished site. For the VMI system to operate, Maruti needs to focus on accurate data sharing with it’s vendors, utilize business intelligence systems to support automated replenishment. Based on continuous monitoring and joint effort, some of the initial bottlenecks could be overcome. To tackle the problem of material accumulation due to multiple sourcing, loss of procurement information and to help achieve systematic levelized production with synchronized supplies, “e-Nagare” system was implemented in January 2003. Nagare means drum in local language. e-Nagare is an electronic version of Kanban system, which has helped in reducing the average inventory through Just-in-Time philosophy. A typical planning system involves making plans at 3 important levels : i) an annual production plan, ii) a fortnight production plan involving a plan each on 1st and 15th of the month followed by a firm delivery schedule sent to suppliers on 5th and 20th of the month, respectively and iii) a firm daily schedule. An e-Nagare system is useful in daily schedule for large voluminous items from local vendors where transit time is just few hours. The vendors of Maruti are connected through extranet to Maruti and they share all data relevant for current production. An yearly schedule is broken down into months and weeks and then passed on to the production department, which then schedules its production program accordingly. For example, an order for a particular day, say, 19th February, involves checking the schedule 2 days before that date, i.e. on 17th February and then an order is placed. In the process, a supplier gets around one day to meet the changes in the schedule. Suppliers are also provided the same copy of the monthly schedule, which is used by MSIL production department. The high level of information sharing helps to counter the amplification in demand variability.The order may be placed via the extranet or on-line portal. After considering the previous day production, available inventory, demand forecast and perceived internal changes in production plan, it calculates and communicates the order for the day-after-tomorrow requirement to the vendors. Most of the vendors are using flexible manufacturing systems(FMS) as it helps automation and provides flexibility to cope with the changes in the requirements by Maruti. By implementing this system the inventory levels in Maruti were reduced initially to seven days and currently has come down to less than a day.

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In the context of the Case above, what are the critical factors,  that have contributed to the successful implementation of VMI system and the consequent reduction in Inventory holding in MSIL?

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