There’s not a day that goes by where you don’t read about the impact of outsourcing on jobs, the economy, an individual company or a market. Outsourcing is here to stay and it’s redefining the way companies operate.
While the headlines about outsourcing focus on jobs and cost savings, those in the trenches know that a host of new challenges get introduced when you outsource. The company outsourcing their manufacturing is still ultimately accountable to the end customer and is defining demand, product introductions, etc. The contract manufacturer is now juggling the requirements of many OEMs and working to provide cost savings and high customer service in the midst of constant changes.
The complexity of today’s supply chains is much greater than in the past. In 1985, the supply chain for a PC manufacturer was quite simple – the end user generated demand to the PC manufacturer/OEM who purchased parts from a semiconductor company. In contrast, the supply chain for a telephone handset manufacturer today includes the end user generating demand with the telephone company, who works with a communications OEM. They in turn outsource the manufacturing to a contract manufacturer who works with a semiconductor manufacturer who works with a foundry.
According to research by the Electronics Supply Chain Association (ESCA), a 10% forecast error in the 1985 PC supply chain produced 21% excess inventory. But in the current telephone handset supply chain, the same 10% forecast error produced 61% excess inventory.
What’s the moral of this story? With spending on consumer electronics on the climb, there’s an increase in volatility (demand, short product lifecycles, increasing margin pressure, etc.) that is making it harder for companies to respond to change. One traditional response mechanism was to carry excess inventory and capacity – but margin pressures don’t allow such “fat” in the system today.
The real challenge is to simultaneously increase customer service levels while improving operating efficiences (less inventory, leaner operations, etc.). To do so, companies need to develop a competency in responding to change. This is the next breakthrough in business performance and many market leaders are already leading the way and seeing the results in both top and bottom line performance.