Development of optimizing application for warehousing management. The case of agro holding vyborgec

Description of the project for optimizing the implementation of warehousing applications, which was launched during its internship at Vyborgets Agricultural Holding. Changes in business processes and assessment of the impact of project implementation.

Рубрика Менеджмент и трудовые отношения
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Язык английский
Дата добавления 04.12.2019
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1

4

3

3

3

2

3

2

4

6

3

3

3

4

5

Q4. Other process stakeholders are satisfied with the process outcomes

2

3

2

2

2

1

2

1

1

3

4

3

2

2

5

Process Enhancement

Q5. You have nothing significant to suggest for current process to enhance it.

2

3

2

3

3

2

3

1

0

2

2

1

4

3

4

Q6. Amount of activities in process is currently optimal

2

3

2

4

3

3

2

2

3

3

2

3

6

3

6

Q7. Your activities create enough value for the company.

4

6

4

5

5

3

7

5

2

3

3

3

4

3

6

Q8. You are currently satisfied with routine you are involved in.

4

3

2

1

1

2

3

2

2

1

1

1

1

2

3

Table 7.

Respondents' answers before project implementation (2)

Category

Question

Respondents

Parameters

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Mean

St. Dev

Process Efficiency

Q1. Current process is done the best way possible.

2

2

2

3

7

2

3

7

7

3

3

5

6

1

1

3

3,097

1,873

Q2. Your working time distributed efficienly.

2

2

2

3

2

1

3

5

3

5

3

1

2

3

2

2

2,323

0,929

Q3. Sunk costs can't be further mitigated easily.

4

4

2

2

2

3

4

7

3

3

5

6

2

6

2

3

3,452

1,411

Q4. Other process stakeholders are satisfied with the process outcomes

3

3

2

3

4

3

3

5

3

1

3

3

2

4

2

3

2,645

1,033

Process Enhancement

Q5. You have nothing significant to suggest for current process to enhance it.

2

3

2

1

2

3

2

1

2

1

3

3

1

3

3

2

2,226

0,940

Q6. Amount of activities in process is currently optimal

3

2

4

2

1

5

3

4

2

3

3

6

3

2

3

2

3,065

1,243

Q7. Your activities create enough value for the company.

3

3

6

3

7

2

5

2

1

3

4

3

3

6

4

7

4,032

1,596

Q8. You are currently satisfied with routine you are involved in.

3

3

2

2

3

4

1

2

2

2

2

4

2

1

3

2

2,161

0,919

As it seemed, employees are not generally satisfied with current state of processes in warehousing - both efficiency and process-wise. Main complains are towards uneven working time distribution and stakeholders' dissatisfaction. During private conversation with employees, author found out that main concerns of stakeholders were overall about product shelf life left on the consumer part and speed of operations in logistics department overall. At the same time employees consider their own impact on value creation inside the company as moderate (while other points lied mostly in range from 2 to 3). Results above clearly depict need in actual changes in processes, not even digitalization introduction in warehousing processes.

Second questionnaire iteration was conducted in almost a month after project realization.

Table 8.

Respondents' answers after project implementation (1)

Category

Question

Respondents

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Process Efficiency

Q1. Current process is done the best way possible.

3

3

4

3

4

5

5

6

4

6

2

4

5

6

6

6

4

4

4

5

Q2. Your working time distributed efficiently.

5

5

4

4

4

5

5

4

5

3

4

6

5

6

4

5

4

5

5

4

Q3. Sunk costs can't be further mitigated easily.

4

3

4

5

5

4

4

4

4

3

4

4

7

5

6

6

2

5

5

4

Q4. Other process stakeholders are satisfied with the process outcomes

5

3

6

4

1

6

7

2

3

5

5

5

4

4

4

5

6

6

5

3

Process enhancement

Q5. You have nothing significant to suggest for current process to enhance it.

4

3

4

3

4

6

4

3

5

5

4

5

6

2

6

6

5

6

7

1

Q6. Amount of activities in process is currently optimal

3

5

4

5

4

4

4

3

4

4

4

5

3

4

3

3

4

3

5

2

Q7. Your activities create enough value for the company.

5

4

7

6

5

4

4

3

5

3

5

2

4

3

5

3

5

5

4

2

Q8. You are currently satisfied with routine you are involved in.

3

3

2

2

1

1

1

2

4

4

1

1

1

3

4

2

3

1

5

4

Table 9.

Respondents' answers after project implementation (2)

Category

Question

Respondents

21

22

23

24

25

26

27

28

29

30

31

32

33

Mean

St. Dev

Process Efficiency

Q1. Current process is done the best way possible.

4

7

5

5

6

4

5

2

4

5

4

7

5

4,606

1,229

Q2. Your working time distributed efficiently.

5

4

2

4

5

4

5

5

3

4

4

5

4

4,424

0,818

Q3. Sunk costs can't be further mitigated easily.

5

4

5

4

4

4

4

5

6

3

5

4

4

4,394

0,983

Q4. Other process stakeholders are satisfied with the process outcomes

4

4

5

4

3

4

6

3

5

5

4

5

3

4,364

1,275

Process enhancement

Q5. You have nothing significant to suggest for current process to enhance it.

3

4

4

3

1

1

4

5

4

3

5

3

7

4,121

1,572

Q6. Amount of activities in process is currently optimal

5

5

5

4

3

1

5

5

4

4

5

3

3

3,879

0,977

Q7. Your activities create enough value for the company.

3

4

5

4

4

5

4

5

3

3

4

6

3

4,152

1,131

Q8. You are currently satisfied with routine you are involved in.

2

3

3

3

3

1

1

3

3

2

4

3

1

2,424

1,155

Even if time periods used for sampling were different - second take was done during the time in between holidays, it is not much affected overall results due to two main factors:

· Company establish discipline among rank-and-file employees;

· Amount of working days in both samplings was identical.

From the results of survey conduction, seems obvious that project realization positively affected almost all the aspects in the list of asked questions - from perceived time expenditure to overall process management. But, in overall, direct comparison of means does not give correct answer. Thus, parametrical tests are required to determine the result. For preliminary calculations, which show pattern of answers - mean (1) and standard deviation (2) (sigma) are needed.

(1)

where: xi - parameter value for particular respondent;

n - sample size.

(2)

where: xi - parameter value for particular respondent;

- estimated mean value for particular parameter.

Paired t-test with equal variances is definitely the way to go in the case of questionnaire results precise identification. Accordingly, all 8 hypotheses (3), connected to questions, are almost the same. Main hypothesis (H0) states that there is no significant difference between means of two samples. Alternative hypothesis (Ha) is `there is a significant difference in favor of situation after project realization".

(3)

To check hypothesis properly, there must be acquired two estimates - critical point and statistic (4). In this case of means comparison, critical point is distributed in Student. Degrees of freedom are equal to: df = 33+31-2 = 62 (Schechtman & Sherman, 2007). With 95% confidential interval and df = 62, critical point becomes closer to 1,67 (MIT Mathematics, 2017).

(4)

where: - estimated mean for sample 1;

- estimated mean for sample 2;

- standard deviation for sample 1;

- standard deviation for sample 2;

- sample size for sample 1;

- sample size for sample 2.

Overall results for hypothesis testing shown in the table below.

In almost all the cases, main hypotheses were accepted, except two questions: "Your activities create enough value for the company" and "You are currently satisfied with routine, you are involved in" - results for these statements are negative - project does not significantly change perception of created value by customer and routine. Both cases can be explained even from the point of psychology: employee does not want show that he is not creating enough cash flow, but quite quick to blame routine activities, while "Process enhancement" is proven to have been influenced significantly by project implementation in general, two aspects does not differ enough to achieve same result.

In terms of consistency and overall applicability of equal-means two-sample t-test for the Likert-type categories, quick equal variance F-test was computed:

For particular sample sizes, critical point is equal to 1,83 with 95% probability (SOCR, 2002). Looking up to tables 6 - 10 makes clear that maximum statistics will be 1,61 in comparison of 2nd question between two samples. Therefore, for all pairs, main hypothesis is accepted = there is no significant difference between variances of two sample in any case.

Table 10.

Results of checking hypothesis

Category

Question

Crit. Alpha

Criteria

Hypothesis accepted?

Crit. Alpha

Criteria

Hypothesis accepted?

Process Efficiency

Q1. Current process is done the best way possible.

2

-3,79

Yes

1,67

- 4,903

Yes

Q2. Your working time distributed efficiently.

2

-9,58

Yes

Q3. Sunk costs can't be further mitigated easily.

2

-3,08

Yes

Q4. Other process stakeholders are satisfied with the process outcomes

2

-5,94

Yes

Process enhancement

Q5. You have nothing significant to suggest for current process to enhance it.

2

-5,89

Yes

1,67

-2,17

Yes

Q6. Amount of activities in process is currently optimal

2

-2,90

Yes

Q7. Your activities create enough value for the company.

2

-0,34

No

Q8. You are currently satisfied with routine you are involved in.

2

-1,01

Yes

In general, implementation of optimizing software for warehousing of Agroholding Vyborgec has overall positive influence on employees' perception of their work routine during participation in processes, directly connected with operations affected by project. Employees report that in terms of sheer efficiency and process quality, warehousing acquired overall improvement with optimizing application introduction after first month of operation.

Financial modelling of application implementation

Open-source and inside financial data was used to create financial model of given application implementation project realization within logistics department of Agroholding Vyborgec. Due to the fact of future cash flow unavoidable uncertainty, there are several assumptions, which are required to complete model with actual state of available information:

1. Unit of production is considered to be on of the following: a kilogram of weighted product; a pack of a product (600-1 000 gram); a 5-pack of green (from 50 to 200 gram in each pack);

2. Production plan is taken from operation department and include given 10% yearly growth in production, distributed on each month, which is justified by ongoing investment projects of Vyborgec, and seasonal drops and peaks in vegetables consumption month by month (for example, in average 40% drop in sales is expected during winter in comparison with summer);

3. As it is calculated during first month of optimization application implementation, there are four significant sources of economy: conveyor transferring time save (about 3 minutes in average); time save in staying inside warehouse (2 hours in average); shipment packaging time save (10 min in average); lesser spoilage (about 9,5% of average inventory instead of 10,5% marked before).

4. Cash flow is projected on a monthly basis.

5. Project cash flow is projected on three-year time horizon (same approach as in Vyborgec).

Also, one of the preliminary steps was to calculate discount rate. Similar to Vyborgec's standards, ROE, adjusted on inflation ratio can be used as a discount rate. ROE was calculated based on financial statement and P&L. Inflation rate was taken from Vedomosty (Vedomosty, 2018) as corrected forecast of Russian Ministry of Economic Development.

Table 11.

Discount rate calculation based on stated assumptions

Parameter

Y1

Y2

Y3

Discount rate (Yearly)

14,06%

13,52%

13,74%

Inflation expectations

4,30%

3,80%

4,00%

Avg ROE (3y)

9,36%

9,36%

9,36%

Table 12.

Financial model of released project in Agroholding Vyborgec (1). First 10 months, savings amount calculated

Month #

0

1

2

3

4

5

6

7

8

9

10

Approx. stock amount at warehouse

683 499

688 949

729 165

790 978

846 675

867 650

788 546

758 705

691 921

624 024

518 000

Units transferred to warehouse (production amount)

-

1 931 835

2 043 264

2 215 025

2 369 445

2 426 556

2 203 881

2 119 092

1 931 298

1 740 643

1 443 956

Units shipped from warehouse

-

1 926 385

2 003 048

2 153 212

2 313 748

2 405 580

2 282 986

2 148 933

1 998 082

1 808 540

1 549 980

Incremental time save from transferring procedures per unit (hours/unit)

-

0,0500

0,0500

0,0500

0,0500

0,0500

0,0500

0,0500

0,0500

0,0500

0,0500

Incremental time save of being in storage for particular pallete (hours/unit)

-

2,0000

2,0000

2,0000

2,0000

2,0000

2,0000

2,0000

2,0000

2,0000

2,0000

Incremental time save of acquring proper pallete for shipping (hours/shipping)

-

0,1670

0,1670

0,1670

0,1670

0,1670

0,1670

0,1670

0,1670

0,1670

0,1670

Average costs of transferring to warehouse per unit/hour

-

0,0028

0,0028

0,0028

0,0028

0,0028

0,0028

0,0028

0,0028

0,0028

0,0028

Average costs of storaging per unit/hour

-

0,0009

0,0009

0,0009

0,0009

0,0009

0,0009

0,0009

0,0009

0,0009

0,0009

Average costs of shipping preparation per hour

-

0,0042

0,0042

0,0042

0,0042

0,0042

0,0042

0,0042

0,0042

0,0042

0,0042

Spoilage percentage decrease

-

0,0100

0,0100

0,0100

0,0100

0,0100

0,0100

0,0100

0,0100

0,0100

0,0100

Average operation margin per unit shipped - unit salvage value

-

0,2810

0,2810

0,2810

0,2810

0,2810

0,2810

0,2810

0,2810

0,2810

0,2810

Savings from transferring

-

271

287

311

333

341

310

298

271

245

203

Savings from warehousing

-

3 146

3 329

3 612

3 866

3 962

3 601

3 464

3 159

2 849

2 365

Savings from shipment preparation

-

1 356

1 410

1 516

1 629

1 693

1 607

1 513

1 406

1 273

1 091

As it is clear, main source of savings is a combination of warehousing processes and spoilage economy. (up to 70%). Economical effect of optimization application is calculated as incremental difference between parameters mean before and after project release. Spreadsheets of average time save in all the cases are not available for publishing. All the calculations were done by author with help of quality control systems by assessing time stamps on each checkpoint for particular pallet.

While table 12 provides insight on income part of cash flow, table 13 shows costs of project incurred at the preparation stage and afterwards.

Table 13.

Financial model of released project in Agroholding Vyborgec (2). First 10 months, costs

Month #

0

1

2

3

4

5

6

7

8

9

10

Investments amount

75 000

-

-

-

-

-

-

-

-

-

-

Licence for basic software

20 000

-

-

-

-

-

-

-

-

-

-

Customization costs

25 000

-

-

-

-

-

-

-

-

-

-

Equipment purchase

30 000

-

-

-

-

-

-

-

-

-

-

Maintenance costs

0

1 051

1 051

1 051

1 051

1 051

1 051

1 051

1 051

1 051

1 051

Education costs

-

26

26

26

26

26

26

26

26

26

26

Training hours

-

8

8

8

8

8

8

8

8

8

8

Cost of 1 hour

-

3

3

3

3

3

3

3

3

3

3

Troubleshooting costs

-

525

525

525

525

525

525

525

525

525

525

Amortization costs

-

500

500

500

500

500

500

500

500

500

500

Corporate tax 20%

0

744

795

877

955

989

893

845

757

663

522

Project has three main sources of costs: beginning investments, maintenance and tax deduction, which will affect overall financial result, if Vyborgec will continue to generate profit. Cash-flow and other key parts of a model will be presented on yearly basis for full length of 3 years.

Maintenance costs include wage of support specialist, costs of external experts who will conduct some trainings in average 1-2 times a week. Amortization costs is calculated with assumption of same linear calculation model applies to the equipment purchase.

Table 14.

Short version of financial model

Year #

Y1

Y2

Y3

Amount at warehouse

714 256

785 682

821 039

Units transferred to warehouse

24 179 621

26 389 467

28 801 276

Units shipped from warehouse

24 148 864

26 318 041

28 765 920

Transferring savings

3 397

3 708

4 047

Warehousing savings

39 509

43 460

47 609

Shipment preparation savings

16 999

18 525

20 248

Investments

75 000

0

0

Maintenance costs

12 615

12 458

12 458

Corporate tax

9 458

10 647

11 889

CF

-37 168

42 588

47 557

DCF

-39 624

35 029

47 557

While company suffers stable amount of losses every period, savings are overcoming losses and give positive cash-flow to the company.

Table 15.

Efficiency indicators of project assessment

Indicator

Amount

NPV

29 818

PI

0,40

PP

23 months

DPP

26 months

IRR

26,80%

NPV was calculated as a sum of positive cashflows along the planning horizon of a project and investment amount. Indicator shows positive score, which tells that project is profitable and economically justified. But, due to the necessity of using units instead of actual currency - rubles, this absolute amount cannot be interpreted, which leaves us with other four indicators. PI is 40%, which shows great case of gain 40% of extra profit over paying cost of capital. Payback periods are varying from 2 to 2,2 years, which is a great result for business, operating mostly on fixed assets and does not achieving fast turnover over time.

Internal rate of return shows considerably good performance, surpassing discount rates more than on 12%, giving opportunity to earn 12% annually over the cost of capital.

3.2 Process state after improvements and recommendations

In terms of process enhancement, optimization application drove several changes in preciously described algorithm (Figure 7):

Figure 7. State of Agroholding Vyborgec process after project implementation3

1. Information lists were changed for bar-code lists to create "stamp" for scanners all over the distribution center to read and write data about any particular bulk which got into distribution center;

2. While guidance inside distribution center is still manual, number of mistakes will decrease due to unambiguous information bar-code keeping inside about route set for the bulk;

3. Storing process of particular bulk is dependent on particular product shelf time and determine actual place, closer to shipping terminals;

4. Employee, armed with scanner, is able to identify needed bulks for particular shipment faster and without mistakes, previously lead to spoilage and losses.

While overall success of changed processes inside distribution center is supported by financial indicators calculation and overall employee perception, there is still a plenty room for improvement:

1. Packing lists and shipment registers are still printed to complete relationships with client in terms of product and payment acceptance and liabilities clearance;

2. Manual bulk steering inside the distribution center still exists and seemed to be unoptimized from the point of additional personnel costs;

3. Production volumes are not responding demand fluctuations inside the month, which still creates space for products spoilage;

As overall positively continuing project, introduction of optimizing application for Agroholding Vyborgec warehousing and logistics needs several improvements to be implemented, based on revelations from previous paragraphs:

· Introduction of storing space with functions of increasing shelf life or product diversification (i.e. introduction of freezed vegetables) according to the fact that current spoilage ratio is still depleting about 9,5% of company's revenue;

· Continue business process optimization with help of "spaghetti diagram" or other instrument to determine most efficient way of moving goods inside distribution center in addition to full automatization of transferring process inside the distribution center;

· Enhancement of application itself is also mandatory: interface is slightly more user-friendly than in MS Excel, analytical reports are not included, other paperwork is not omitted - introduction of digital systems of document exchange with clients and other departments is a clear next step for Agroholding Vyborgec to improve warehousing and logistics operations.

Conclusion

Looking at the big picture of Russian economy current state will reveal strong need in acquiring additional competitive advantages not only inside the market, but also in international operations. Digitalization may support traditional methods of obtaining competitive advantage or company overall sustainability: fixed assets renovation, operation shrinking and simple cost-cutting. Holistic effect of warehousing application usage can not only decrease unit costs, improve quality control state or optimize assets capacity utilization, but also provide company with corporate culture establishing by showing employees that assuring process effectiveness it one of the company values. That fact alone may construct the foundation of internal projects execution, driven mainly by employees, not managers.

For Agroholding Vyborgec, one of the main benefits of research competition is the knowledge about project effectiveness on various levels, from plain financial numbers to the feeling of actual warehousing employees who will embrace changes in their everyday routine. Level of that embracement will be depicted by qualitative data analysis. Multicriterial estimation will give edge for Vyborgec to tune future digitalization implementation activities or perform better change management processes in other fields of management.

Possible future research options for the topic may lie in the field of studying effects of digitalization in yearly time perspective (2-3 years after implementation) or in implementing consimilar approach in other Agroholding Vyborgec operations like HR or Marketing to find additional way to improve company financial performance.

From the point of research objectives - all of them were accomplished by this paper:

· Current state of warehousing optimization topic is given through prism of internet-of-things and overall digitalization;

· State-of-art of Agroholding Vyborgec thoroughly described, analyzed and used to create framework for measuring project effectiveness;

· Data collected, processed; relevant methods used and indicators calculated to provide overall conclusion on the optimization application solution effectiveness;

· Business processes compared, various recommendation, based on the previous analysis are provided.

Answering research problem: with help of literature review, author came to conclusion that under given data and circumstances, project financial effectiveness and qualitative assessment of state by process participants are sufficient to determine project effectiveness. While project pays back investments made during approximately two-year time period, positive NPV, which creates additional 40% income over three years above required rate of return, clearly states that from financial point of view, project is profitable and will have overall positive take on company warehousing and logistics operations. In the same time, employees responded with assertive perception of being a part of warehousing processes after project implementation.

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Appendices

Appendix 1.

Financial Statement of Agroholding Vyborgec for 2016 - 2017 (1)

Наименование

Величина

ОКПО

23377011

ИНН

4703006839

Код единицы измерения (384 - тыс.руб, 385 - млн.руб)

384

11103 Нематериальные активы на конец отчетного года

312

11104 Нематериальные активы на конец предыдущего года

448

11503 Основные средства на конец отчетного года

4956783

11504 Основные средства на конец предыдущего года

3204816

11903 Прочие внеоборотные активы на конец отчетного года

2745

11904 Прочие внеоборотные активы на конец предыдущего года

1688

11003 Итого внеоборотных активов на конец отчетного года

4959840

11004 Итого внеоборотных активов на конец предыдущего года

3206952

12103 Запасы на конец отчетного года

440967

12104 Запасы на конец предыдущего года

276856

12203 Налог на добавленную стоимость по приобретенным ценностям на конец отчетного года

5030

12204 Налог на добавленную стоимость по приобретенным ценностям на конец предыдущего года

23037

12303 Дебиторская задолженность на конец отчетного года

706091

12304 Дебиторская задолженность на конец предыдущего года

505877

12403 Финансовые вложения (за исключением денежных эквивалентов) на конец отчетного года

174944

12503 Денежные средства и денежные эквиваленты на конец отчетного года

247239

12504 Денежные средства и денежные эквиваленты на конец предыдущего года

11423

12603 Прочие оборотные активы на конец отчетного года

6883

12604 Прочие оборотные активы на конец предыдущего года

5672

12003 Итого оборотных активов на конец отчетного года

1581154

12004 Итого оборотных активов на конец предыдущего года

822865

16003 БАЛАНС (актив) на конец отчетного года

6540994

16004 БАЛАНС (актив) на конец предыдущего года

4029817

13103 Уставный капитал (складочный капитал, уставный фонд, вклады товарищей) на конец отчетного года

51

13104 Уставный капитал (складочный капитал, уставный фонд, вклады товарищей) на конец предыдущего года

51

13403 Переоценка внеоборотных активов на конец отчетного года

115196

13404 Переоценка внеоборотных активов на конец предыдущего года

123421

13703 Нераспределенная прибыль (непокрытый убыток) на конец отчетного года

632130

13704 Нераспределенная прибыль (непокрытый убыток) на конец предыдущего года

584877

13003 ИТОГО капитал на конец отчетного года

747385

13004 ИТОГО капитал на конец предыдущего года

708357

14103 Долгосрочные заемные средства на конец отчетного года

4489790

14104 Долгосрочные заемные средства на конец предыдущего года

2465769

Financial Statement of Agroholding Vyborgec for 2016 - 2017 (2)

Наименование

Величина

14503 Прочие долгосрочные обязательства на конец отчетного года

61

14504 Прочие долгосрочные обязательства на конец предыдущего года

261

14003 ИТОГО долгосрочных обязательств на конец отчетного года

4489851

14004 ИТОГО долгосрочных обязательств на конец предыдущего года

2466030

15103 Краткосрочные заемные обязательства на конец отчетного года


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