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Strategic Sourcing Case Study – Wind Turbine Industry
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160 suppliers were initially identified, finally 12 suppliers submitted an RFI-RFQ response
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Strategic Sourcing Case Study – Wind Turbine Industry
1.
Dragon Sourcing Your Tailored
Approach to Emerging Markets Strategic Sourcing Case Study – Wind Turbine Industry June 20th 2014
2.
Agenda 1. Objectives ,
work plan and time line 2. Approach 3. Results © 2014 Dragon Sourcing. All rights reserved. 2
3.
Objectives Context Client overall objectives
: Identify new potential competitive suppliers in China and India who can supply items at delivered prices 15-20% below current levels (maintain/improve safety, quality and delivery at lower cost) Categories involved • Blades – 1.Plastic injection moulded items – 2. Small plastic parts – 3.Covers • Electricals – 4.LV-Cable / MV-cable – 5.Slip Ring Brush holder • Mechanical – 6.Plate heat exchanger / Water cooler – 7.Blower and fan – 8.Internal crane – 9.Fasteners – 10.Machined + Sheet Metal components • Power train – 11.Brake – 12.Shrink Disc • Towers – 13.Tower flanges – 14.Steel plates – 15.Platform & Alu parts – 16.Steel parts and Magnets – 17.Access and Safety Equipment • WCS – 18.Yaw Gears – 19.Yaw Motors – 20.Pipes, hoses and fittings – 21.Yaw Ring and Blade Bearing Dragon Sourcing approach 1. Demand Analysis: Work with Client to define and understand the products and requirements (specs, volumes, materials, production technology requirements) 2. Supply Market Analysis: Identify long list of potential suppliers in China and India by leveraging B2B Websites, DS Database, Fair catalogues, Chamber of Commerce, Magazines, Network, References. 3. Telephone Pre-screening: Selection of suppliers to be included in the RFI/RFP process by telephone pre-screening based on agreed simple criteria (e.g. capability to make the product, minimum company size, interest in participating) 4. Administer the NDA: Administration and chasing for completion of the NDA with suppliers that have been preselected 5. Develop RFI/RFP & Scorecard template: Prepare an RFI/RFP document, with an aligned Balanced Scorecard that has the objective to pre-qualify the capabilities of the suppliers, including: Background, Financials, Client and product experience, Quality certification & processes, Social Responsibility, Manufacturing/technology capability 6. Administer the RFI/RFP: The RFI/RFP is distributed to the relevant suppliers who have signed NDA, with telephone follow-up to push for maximum participation. 7. Analyze RFI /RFP Responses: Analysis of RFI/RFP responses to objectively rank the suppliers by capability and competitiveness, and to develop sense for price points 3© 2014 Dragon Sourcing. All rights reserved.
4.
MilestonesStarted FinishedNot-started Delayed The
project was carried out in 3 months Steps Who 3/10 - 3/14 3/17- 3/21 3/24- 3/28 3/31-4/4 4/7-4/11 4/14- 4/18 4/21- 4/25 4/28-5/2 5/5-5/9 5/12- 5/16 5/19- 5/23 5/26- 5/30 6/2-6/6 6/9-6/13 0 Kick off meeting Client/ DS 1 Demand Analysis: Client/ DS 2 Supply Market Analysis: DS 3 Telephone Pre-screening: DS 4 Administer the NDA: DS 5 Develop RFI/RFQ & Scorecard template: Client/ DS 6 Administer the RFI/RFQ DS 7 Analyze RFI /RFP Responses: Client/ DS TOD 4© 2014 Dragon Sourcing. All rights reserved. Phase 1 Phase 2
5.
Whole project progress
was closely tracked. © 2014 Dragon Sourcing. All rights reserved. 5 On timeDelayedSchedule 7.7% 15.4% 23.1% 30.8% 38.5% 46.2% 53.8% 61.5% 69.2% 76.9% 84.6% 92.3% 100.0% 7.7% 17.2% 23.8% 30.5% 36.1% 41.5% 47.1% 55.7% 64.0% 0% 20% 40% 60% 80% 100% 3/17-3/21 3/24-3/28 3/31-4/4 4/7-4/11 4/14-4/18 4/21-4/25 4/28-5/2 5/5-5/9 5/12-5/16 5/19-5/23 5/26-5/30 6/2-6/6 6/10-6/14 Sourcing General Progress Schedule Actual
6.
Agenda 1. Objectives ,
work plan and time line 2. Category Approach (Tower flange example) 3. Results © 2014 Dragon Sourcing. All rights reserved. 6
7.
The RFQ included
5 items representative of the total spend comprised of 19 items. © 2014 Dragon Sourcing. All rights reserved. 7 General description Material Mass Weight per pcs. (kg) Annual quantity (pcs) Tower Flange Dia4450/3850*110 S355NL 1733 260 Tower Flange Dia2316/2070*370 S355NL 1258 520 Tower Flange Dia4173/3793*115 S355NL 1213 520 Tower Flange Dia4167/3785*105 S355NL 1101 520 Tower Flange Dia3364/3032*90 S355NL 617 260
8.
160 suppliers were
initially identified, finally 12 suppliers submitted an RFI-RFQ response © 2014 Dragon Sourcing. All rights reserved. Progress China India Suppliers identified 91 69 Suppliers called 91 69 Suppliers passed pre-screening 14 10 Suppliers NDA sent 14 10 Suppliers NDA received 11 6 Suppliers RFI/RFQ received 6 3 8
9.
Balance Score card
used to rank the suppliers © 2014 Dragon Sourcing. All rights reserved. Business information Weight of criteria Scoring Max Score per criteria Section weight Year Founded 10% 1=After 2010 2= >=Between 2006 to 2010 3= >=Between 2000 to 2005 4= >=Between 1995 and 1999 5=Before 1995 5 15% Registered capital in USD 10% 1=Less than 5M 2= >=Between 5to 10M 3= >=Between 10 to 20M 4= >=More than 20M 4 Turnover in 2013 in USD 20% 1=Less than 10M;2= >=10M-50M 3= >=50M-100M; 4= >=100-200M 5=Above 200M 5 Export experience 10% 1=Less than 5 years;2=>=5-10 years 3=>=More than 10 years 3 Profile of client in wind turbine industry 25% 0=Not provided ;1=Local customers 2=National customers 3=International customers as Client 3 Profile of Top Customers 25% 0=Not provided ;1=Local customers 2=National customers 3=International customers 3 Subtotal 100% 15% Production Weight of criteria Scoring Max Score per criteria Section weight Monthly production capacity of flange ( diameter more than 2 m) 10% 1=Below 100pcs ; 2=100-500pcs 3=500-1000pcs;4=Above 1000pcs 4 35% Global prodction facilities 10% 1=No; 2= Production facilities in two countries ; 3= More than two countries 3 All production steps in house 10% 0=No 2=Yes 2 Production with S355 NL EN 10025-3 10% 0= No 1= Yes 1 Ring Rolling Mill - outer diameter up to 5000mm. 10% 0= No;1= 1-3 machines 2= 4-6 machines; 3= >=7 machines 3 Forging Press above 3000 tons 10% 0= No; 1= 1-3 machines 2= 4-6 machines 3= >=7 machines 3 CNC MACHINING CENTER 10% 0= No; 1= 1-5 machines 2=>=5-10machines; 3= >=10 machines 3 Vertical turning 10% 0= No;1= 1-10 machines 2= 10-20 machines ; 3= >=20 machine 3 Heat Treatment Furnace 10% 0= No;1= Yes 1 Numbers of Employees 10% 0=less than 100;1= 100-300 2= 300-500 ; 3= above 500 3 Quality system Weight of criteria Scoring Max Score per criteria Weight of the section ISO 9001 20% 0= No ; 1= Yes 1 35% ISO 14001 10% 0= No ; 1= Yes 1 CE Certificate 10% 0= No ; 1= Yes 1 OHSAS18001 10% 0= No ; 1= Yes 1 IQC, IPQC, FQC report 10% 0= No ; 1= Yes 1 Warranty term 10% 0= No description 1= Simple, not very clear 2= Detailed, clear 2 3D measurement 15% 0= No ; 1= Yes 1 ultrasonic inspection 15% 0= No ; 1= Yes 1 Subtotal 100% 35% Cooperation Weight of criteria Scoring Max Score per criteria Weight of the section Cooperation during NDA,RFI/RFQ 50% 1= Poor 2= Satisfactory 3= Excellent 3 5% Completeness of RFI/RFQ 50% 1= Poor 2= Satisfactory 3= Excellent 3 Subtotal 100% 5% Price Competitiveness Weight of criteria Scoring Max Score per criteria Weight of the section Quote all items 10% 1= Partial 2= All 2 10% Each Item has saving or not 10% 0= No saving 1= Partial 2= All 2 Payment term 20% 1= Don't accept Client payment term 2=Accept 2 Saving of tower flange 60% 0=No savings 1=Savings less than 5% 2=Savings between 5% to 10% 3=Savings between 10% to 15% 4=Savings over 15% 4 Subtotal 100% 10% 9
10.
Savings were identified
in both countries © 2014 Dragon Sourcing. All rights reserved. 10 Current spend Suppliers without savingSuppliers with saving M Euro 5.81 4.52 4.75 5.00 5.30 5.55 7.82 4.82 5.26 6.78 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 Current China - Supplier 1 China - Supplier 2 China - Supplier 3 China - Supplier 4 China - Supplier 5 China - Supplier 6 India - Supplier 1 India - Supplier 2 India - Supplier 3 Suppliers annual spend comparison
11.
81 80 73 67 62 58 78 66 57 4.75 5.00 4.52 5.55 5.30 7.82 5.26 4.82 6.78 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 0 10 20 30 40 50 60 70 80 90 China - Supplier
2 China - Supplier 3 China - Supplier 1 China - Supplier 5 China - Supplier 4 China - Supplier 6 India - Supplier 2 India - Supplier 1 India - Supplier 3 Tower Flange Supplier Scorecard and Annual Spend Overview RFI/RFQ score Annual spend ..and 7 suppliers were recommended for auditing. © 2014 Dragon Sourcing. All rights reserved. 11 M Euro
12.
Company profile xxxxxxx © 2014
Dragon Sourcing. All rights reserved. 12 COMPANY INFORMATION Company Name xxxxxxx Address xxxxxxx Town xxxxxxx Province xxxxxxx Company Website xxxxxxx CONTACT PERSON INFORMATION Contact Person xxxxxxx Title xxxxxxx Email xxxxxxx Tel xxxxxxx Fax xxxxxxx Mobile phone xxxxxxx BUSINESS INFORMATION What date was your company founded? 1998 How much is your registration capital (RMB)? 160million What's the nature of your company? (Private, state owned, joint venture, etc) Joint Venture What is your turnover in million RMB ? 2014 ( to date) 2013 2012 2011 683.69 1356.33 1282.05 1452.93 How many square meters(m²) does your factory occupy ? 1100000 How many employees do you have? 1100 How many employees can communicate in English? 65 Does your company have an export license ?(yes or no) Yes How many years of export experience do you have? 16 What industry does your company mainly serve? Power generation, electric power , transmission, environmental protection , pressure vessels and steel structure Do you have subsidiaries outside China? If yes, where? No Do you supply products to wind turbine industry? If yes, how many years? Yes,11 years Percentage of you turn over coming from Wind Turbine Industry? (%) 30% Who is your main customer in wind trubine industry? Datang, Longyuan, China Power Investment, Huaneng Do you have European / international customers? If yes, which ones? ? No What is the percentage of turnover distributed to: Domestic Europe US Rest of the World 97.6% 1.0% 1.0% 0.4% Who are your top 3 Clients? Clients Industry Country % of sales 1 SGCC Power Plant China 55% 2 Datang Wind Power China 13% 3 Huaneng Wind Power China 7% CORPORATE RESPONSIBILITY Shortly describe your policy to cover environment and conservation. ISO14001 Shortly describe your policy to cover health and safety. OHSAS18001 Shortly describe your policy to cover human rights. Respect human rights & object discrimination to staff Shortly describe your policy to cover business ethics and anti-Bribery. follow the principle of fair competition, no bribery, respect the objective facts PRODUCTION What's your main products? Tower Flange Tower Flange Dia. 2-5m Tower Flange Dia. Over 5m Tower Flange Monthly production capacity( pcs ) 2000 1500 500 What is current free monthly production capacity (pcs)? 1400 1050 350 How many production facilities does your company have worldwide? 1 If you have more than 1 production facility worldwide, please list their address and production capacity. Address Monthly capacity 1666 Does your company do all production steps in house? Yes Does your company produce right listed products fow wind power industry in house? (Yes/No) Yaw ring Blade bearing Tower flange Yaw gear Big machined parts Metal parts (stamping,p unching,etc ) N N Y N Y Y RFI/RFQ score 81 Ranking 1
13.
Company profile xxxxxx © 2014
Dragon Sourcing. All rights reserved. 13 Equipment list(If you have more than three kind, please insert needed row) Equipment description and brand Max processing dimension mm ( X,Y,Z) Quantity CNC MACHINING CENTER CNC Drill Lathe 5000x5000x400 2 High speed CNC Drill Lathe 5000x5000x400 2 Equipment list(If you have more than three kind, please insert needed row) Equipment description and brand Max processing dimension mm ( X,Y,Z) Quantity Vertical turning CNC Drill Lathe 5000x5000x1200 6 Vertical Lathe 3500x3500x1200 2 Vertical Lathe 5000x5000x1500 10 Does your company have right listed processing in house? Forging Casting Stamping Welding Heat treatment N Y Y Y Y Do you have production equipment list? Yes If yes, please provide equipment list. Worker Engineer R&D Quality Control Manageme nt Sales How many people do you have in these positions? 56 22 5 9 5 2 How many of those speak and write english? 0 4 5 3 3 2 How long does your employee work in your company in average? 8 years How many shift does your company work? How many hours one shift? 8h/shift, 2 shifts Quality, Environmental and Product Certification Do you have below certificates ? Yes / No Date of Certificate Certifying Org. Manufacturing QMS ISO 9001 Yes 2013.2.5 CQM ISO 14001 Yes 2013.2.5 CQM OHSAS18001 Yes 2013.2.5 CQM What international/domestic product certification do you have? Gamesa Yes 2012.8 Gamesa CE Yes 2013.5..24 TUV NORD BV Yes 2012.4.26 BV Pressure piping components Yes 2013.9.30 AQSIQ Do you have incoming material inspection and report? ? Yes Do you have daily on line quality inspection(Y/N)? How often do you have these inspection as well as on which production stages the inspection to be conducted? ? Yes,100% What type of inspection to be conducted(100% or sample inspection)? 100% inspection Do you have final products inspection and report? Yes What performance do you achieve on average in out going quality measures (% rejected)? 1.20% What's the warranty term of your Tower Flange? 3.1 certificate What is your internal rule regarding maximum reaction time of quality claim? 24h Do you accept 3rd party QC? Yes How long do you keep the QC records? 1-20 years Which test does yor company corporate with an external supplier? No Test Yes / No Equipment brand Quantity Please list quality control equipment that you have in- house Ultrasonic inspection Yes Jinan Shidai 2 Magnetic particle detector Yes Jinan Shidai 3 spectrometer Yes Belec 1 infrared thermometer Yes Xi’an 3 Hardness Tester Yes Laizhou 1 Metallurgical microscope Yes Chongqing Opitical 1 Impact Tester Yes Jinan Kehui 1
14.
Company certificate and
picture xxxxxxx 14 Business registration Tax registration Organization Code certificate Factory entrance Workshop Machinery Machinery Warehouse Office © 2014 Dragon Sourcing. All rights reserved. 14
15.
Agenda 1. Objectives ,
work plan and time line 2. Approach 3. Results © 2014 Dragon Sourcing. All rights reserved. 15
16.
In total, nearly
3000 suppliers were identified resulting in 147 suppliers to be audited © 2014 Dragon Sourcing. All rights reserved. 16 Started FinishedNot-started China sourcing India sourcing # FG Category Supplier list # of supp pass Tel Pre- screen NDA received RFI/RFQ received Suppliers to be audit Supplier list # of supp pass Tel Pre- screen NDA received RFI/RFQ received Suppliers to be audted 1 Blades Plastic Injection moulded parts 58 17 11 4 1 67 4 4 2 2 2 Small plastic parts 47 30 11 7 4 58 Cancel 3 Covers 46 12 10 8 5 64 10 5 2 2 4 Electricals LV-Cable / MV-cable 159 36 10 6 4 91 23 13 5 5 5 Slip Ring Brush holder 68 18 15 3 3 25 13 8 1 1 6 NLE Plate heat exchanger / Water cooler 170 43 30 13 11 136 38 22 5 3 7 Blower and fan 80 28 22 5 5 58 21 12 2 2 8 Internal crane 63 11 7 4 4 54 13 5 3 3 9 Fasteners 77 25 14 5 5 63 18 8 3 3 10 Machined + Sheet Metal components 78 18 13 7 4 106 30 22 5 6 11 Power train Brake 61 23 14 9 6 70 8 5 2 2 12 Shrink Disc 37 13 12 6 5 25 5 4 2 2 13 Towers Tower flanges 91 14 11 6 5 71 10 6 3 2 14 Steel plates 51 7 7 6 6 57 9 7 4 4 15 Platform & Alu parts 41 7 7 2 2 52 16 11 1 1 16 Steel parts and Magnets 96 42 Cancel 46 18 12 6 6 17 Access and Safety Equipment 60 20 18 10 6 67 10 3 2 2 18 WCS Yaw Gears 56 16 13 6 4 62 21 9 3 3 19 Yaw Motors 83 27 20 15 8 69 15 9 4 4 20 Pipes, hoses and fittings 140 45 15 2 2 71 15 8 2 2 21 Yaw Ring and Blade Bearing 38 Cancel 64 10 8 2 2 Total 1600 452 260 124 90 1376 307 181 59 57
17.
Lessons learned: don’t
make the NDA too stringent and have precise drawings and specs available; in this programme 10% of identified suppliers were lost in the process for these reasons © 2014 Dragon Sourcing. All rights reserved. China sourcing India sourcing # FG Category Supplier would not sign NDA Spec were not sufficient to make reliable quote Supplier would not sign NDA Spec were not sufficient to make reliable quote 1 Blades Plastic Injection moulded parts 6 1 0 0 2 Small plastic parts 19 0 3 Covers 2 1 5 4 Electricals LV-Cable / MV-cable 26 0 10 3 5 Slip Ring Brush holder 3 6 5 5 6 NLE Plate heat exchanger / Water cooler 13 0 16 0 7 Blower and fan 6 2 9 0 8 Internal crane 4 0 8 0 9 Fasteners 11 1 10 0 10 Machined + Sheet Metal components 5 0 8 0 11 Power train Brake 9 0 3 0 12 Shrink Disc 1 1 1 2 13 Towers Tower flanges 3 0 4 0 14 Steel plates 7 0 2 0 15 Platform & Alu parts 0 0 5 0 16 Steel parts and Magnets 6 0 17 Access and Safety Equipment 2 3 7 0 18 WCS Yaw Gears 3 0 12 7 19 Yaw Motors 7 0 6 0 20 Pipes, hoses and fittings 30 1 7 0 21 Yaw Ring and Blade Bearing 2 0 Total 157 16 126 17 17
18.
Most categories offered
potential savings, especially in China © 2014 Dragon Sourcing. All rights reserved. 18 China saving summary India saving summary # FG Category % Min saving % Max saving % Min saving % Max saving 1 Blades Plastic Injection moulded parts - - - - 2 Small platic parts 64% 80% - - 3 Covers - - - - 4 Electricals LV-Cable / MV-cable 24% 24% 5% 5% 5 Slip Ring Brush holder 21% 71% 81% 81% 6 NLE Plate heat exchanger / Water cooler 9% 33% - - 7 Blower and fan 16% 52% 4% 7% 8 Internal crane 7% 47% 22% 41% 9 Fasteners 9% 52% 47% 80% 10 Machined + Sheet Metal components 6% 17% 0.1% 4% 11 Power train Brake 15% 75% 3% 21% 12 Shrink Disc 3% 32% 4% 9% 13 Towers Tower flanges 4% 22% 8% 14% 14 Steel plates 6% 25% - - 15 Platform & Alu parts 6% 54% 0.5% 0.5% 16 Steel parts and Magnets Not done - - 17 Access and Safety Equipment 15% 42% - - 18 WCS Yaw Gears - - - - 19 Yaw Motors 1% 53% - - 20 Pipes, hoses and fittings 19% 33% 22% 30% 21 Yaw Ring and Blade Bearing Not done - - Total 7% 29% 5% 9%
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