OM in the News: The Pig Supply and Demand Problem

“The American pork industry has a problem: It makes more tenderloin, ham, sausage and bacon than anybody wants to eat,” writes The Wall Street Journal (Feb 10-11, 2024). 

If younger Americans don’t start buying more pork, annual consumption will drop by 2.2 pounds per capita over the next 10 years.

From giant processors to the farmers who supply them, they are in a predicament largely of their own making. They made production so efficient that demand can’t keep up with supply. U.S. demand for pork is 9% less than what it was 20 years ago, but farmers produce 25% more.

The rise of industrial-scale hog farms, steadily increasing crop yields and growing overseas demand helped supercharge the U.S. pork industry in the late 20th century, and since the 1980s, pork production in the U.S. has doubled. The industry will produce nearly 28 billion pounds of pork this year, cleaved from roughly 125 million hogs.

Pork contributes $57 billion to the U.S. economy and employs 610,000 people. In Iowa, the top pork-producing state, hogs outnumber people nearly 8 to 1. That zeal for efficiency and expansion are a factor in the current troubles. Practically everything that goes into raising hogs is now significantly more expensive: machinery, services, equipment, repairs, building materials, livestock-feed supplements and labor.

In the 1960s and early ’70s, beef was king among American consumers and pork held second place, but chicken overtook pork in 1986 as poultry production skyrocketed, making it the cheapest of the big three meats. By 1993, chicken became the most-eaten meat in America. Religious prohibitions in Judaism and Islam limit pork’s popularity, along with a sense among some that pigs are too smart to slaughter. On the other hand, some consumers are more passionate about their love for bacon than any other meat.

So American pork producers increasingly bank on consumers in other countries. The industry exports 25% to 30% of product. Sales to China, the world’s top pork-eating nation, surged following a hog-disease outbreak in the country in 2018. Producers in the U.S. responded by expanding capacity even further, with new processing plants in Iowa and Michigan. Chinese pork producers rebuilt their herds, however, and exports to the country have plummeted over the past two years, contributing to U.S. oversupply and pressuring meatpackers’ profits.

Classroom discussion questions:

  1. What options do pork producers have? (Hint: see Supp. 7 in your Heizer/Render/Munson text on page 308)
  2. How has technology played a role in the imbalance?

OM in the News: Is Allegiant Really One of America’s Best Airlines?

Perhaps surprising to students and professors who fly a lot, Allegiant Air took 3rd in The Wall Street Journal’s (Feb. 8. 2024) annual airline scorecard, which ranks nine major carriers on their operational performance.

It’s the highest finish for the Las Vegas-based no-frills airline. The smallest carrier in the rankings scored well in the categories of (1) fewest mishandled bags, (2) fewest cancellations and (3) fewest passengers involuntarily denied boarding.

Flying Allegiant does mean accepting limitations. Some routes are only available twice a week. If there is a cancellation, travelers could be stuck for days. It charges a host of fees for add-ons—picking a seat assignment, bringing a carry-on bag or even ordering a premium beverage. But Allegiant only flies nonstop, meaning fliers can avoid annoying layovers that increase the chances of a trip gone wrong.

Allegiant has grown more reliable. In 2022, it canceled 4.25% of its flights, the most of any airline in the WSJ rankings, and fewer than 2/3 of its flights arrived on time. It finished 5th overall in that 2022 rankings. In 2023, the airline canceled less than 1% of its flights and improved its on-time arrival percentage to 72.8%—10 points up from the year before. (Allegiant still finished 6th of 9 carriers for on-time arrivals.)

So what are its operation management advantages? First, Allegiant flew its planes for about 7.5 hours per day in 2023, hours less than Spirit and Frontier, which are its low-budget competitors. That relative infrequency gives Allegiant more time to recover if things do go wrong. Second, Allegiant flies less than Frontier and Spirit. It had 115,500 flights scheduled in 2023—60% of Frontier’s total and 38% of Spirit’s. Third, unlike Spirit and Frontier, Allegiant doesn’t oversell its flights, so it didn’t bump a single passenger last year. It also placed first in baggage.

Allegiant placed 5th in complaints in the rankings. It says it plans to add more self-service tools so customers can make changes on their own, as well as add more precise callback features. Allegiant had a higher rate of delayed flights than the larger airlines because of the infrequency of its routes and the fact that it frequents smaller airports. The airline says it would rather delay flights than cancel them.

Classroom discussion questions:

  1. From an OM perspective, what is Allegiant doing well? Why?
  2. How can it improve its perceived quality?

OM in the News: Maintenance Really Does Count

When Ural Airlines Flight 1383 to Siberia suffered a technical fault with its hydraulics a few months ago, the pilots decided to divert to a closer airport. Then they discovered the defect meant the aircraft was rapidly running out of fuel and needed to land quickly. The plane, with 165 people onboard, eventually made a successful emergency landing in a farm in southern Russia. The Airbus A320 jet remains there, fenced in and under security, with Ural agreeing to pay rent for a year to the land’s owner–and then harvesting the jet for parts.

The episode is among a surge in aviation-safety incidents recorded in Russia last year, and an indication of how Western sanctions are hindering the country’s ability to source spare parts and conduct proper maintenance, writes The Wall Street Journal (Feb.5, 2024). (See Chapter 17 in our text).  Some 74 air safety incidents were logged in Russia last year, up from 36 in 2022. The data show an incident occurred 9.9 times in every 100,000 departures in 2023, compared with 5.0 in 2022 and 4.5 in 2019. The incidents include repeated instances of engines catching fire or becoming inoperative during a flight, rubber landing-gear tires bursting during landings, and malfunctioning flaps leading to diversions.

Sanctions imposed after Russia’s invasion of Ukraine have cut off that country’s access to Western aircraft manufacturers, banning the provision of spare parts, maintenance support, critical software updates and more. “The sanctions imposed on Russian airlines have significantly impeded the maintenance of aircraft airworthiness and their technical condition,” said one industry expert.

Russia is particularly exposed to shortages of landing gear and brakes, and has had to send aircraft to Iran for maintenance. And a lack of technological know-how in repairing wheels and separate issues with low-quality deicing chemicals have led to safety incidents. Meanwhile, a shortage of parts for simulators limit Russia’s ability to train new pilots and run required refresher courses.

The deterioration of Russia’s aviation safety record is undoing decades of work by Russia’s airlines to modernize their fleets and turn around a reputation for questionable safety. That effort started in the early 2000s, when Russian airlines spent billions of dollars buying brand-new Boeing and Airbus jets to replace aging and less-reliable Soviet-era aircraft. The splurge left Russia with one of the biggest aircraft fleets in the world– a total of 1,031, most built by Airbus and Boeing. Russia’s total operational fleet is forecast to halve by 2026.

Classroom discussion questions:

  1. What are the two types of maintenance issue that Russia airlines face?
  2. How does Figure 17.2 (Overall System Reliability) apply in this case?

OM in the News: Shipping Dangers on the High Seas

Ships today handle more than 80% of global goods. And the modern economy rests on the rule that ships of any nation may sail the high seas. “Suddenly, that pillar of the international order shows signs of buckling,” writes The Wall Street Journal (Feb 1, 2024). 

In the Red Sea, Houthi rebels have stormed onto cargo ships, causing freight rates to quadruple and setting a precedent that American vessels aren’t welcome across one of the world’s most vital transport lanes.

Open oceans allowed a global economy to emerge from the wreckage of two world wars. The freedom for all container ships to safely ferry goods on the high seas helped lift China from poverty, turn the U.S. into a country of middle-class consumers and cement the dollar as the world’s reserve currency. Until the 20th century, trading nations competed in blood for the right to ship merchandise to foreign ports; these days they compete on price and quality.

Only eight decades separate the present from a past when most manufactured goods moved by land and a ship was only as safe as the state protecting it. Less than 500 million tons of dry cargo crossed the seas annually in the 1950s. That world was dotted with small manufacturers serving local buyers. Today, container ships carry  23 times more tonnage, integrating a global economy of mammoth conglomerates targeting whichever customer on earth offers the most profit, soonest. That integration has driven down costs, allowing IKEA to cheaply sell identical sofas in 59 countries and McDonald’s to fry Idaho’s Russet Burbank potatoes around the world.

But it has also made car factories, big-box retailers, fashion houses and electronics dealers significantly more vulnerable to even the smallest snags: Witness the tens of billions of dollars in trade held up when a single cargo ship, the Ever Given, ran aground in the Suez Canal for six days of 2021. Or the supply-chain breakdown that unfolded as the Covid-19 pandemic left container ships log-jammed outside Asian and American ports.

Governments from Europe to Asia that have grown prosperous and accustomed to safe seas want to keep maritime chokepoints open, particularly the Suez Canal, the Taiwan Strait and the Horn of Africa. Worldwide, the average cost of shipping a 40-foot container has jumped 2.7-fold in the past 3 months, to $3,964.

Classroom discussion questions:

  1. What can operations managers do to address this risk?
  2. In Supp. 11 of your Heizer/Render/Munson text (see page 477), transportation mode analysis is introduced. How can this model be used to deal with Red Sea disruptions/costs/dangers?

Guest Post: Repurposing Military Bases

Prof. Howard Weiss developed the Excel OM and POM software that we provide free with our text.

In previous blogs for your Heizer/Render/Munson text, I have written about both failures and successes in repurposing facilities. The US has been successful in repurposing many of the more than 350 bases that the military has closed since 1988, saving over $500 million dollars due to these closures. But it is not a simple matter.

Safety Concerns While no two bases are alike, several are contaminated with toxic solvents, lead, radioactive materials, asbestos, and explosives residue. The US has spent over $1 billion dollars to address these issues and has been successful with remediation of the problems at some, but not all, of the installations. Remediating is not always a quick and easy process. For example, the groundwater at Lowry Air Force Base in Denver is not expected to be cleaned up until 2084. Another safety issue is that of unexploded ammunition.

Remediation It is challenging to remediate any facility. Environmental standards are stricter today, such as the use of asbestos in buildings, than when these bases were built. And there has been an increase over time in the number of local, state and the federal government environmental regulations. Some of the current laws apply specifically to base remediation while others refer to any organization. Another challenge is that remediation plans may need to be approved by several different government offices.

Uses There have been many different uses of closed installations. Several are still used for some military purpose such as training for the National Guard or veteran services. Other uses include office space, homes, apartments, schools, businesses, parks, golf courses, arts and fitness centers, movie sets, production studios, training centers, a university, an international airport, corporate headquarters and a prison. Military Shipyards are different from normal installations, so private companies have taken them over in Charleston and Philadelphia. Shipyards can also be used as a container port.

Leasing Companies do not need to wait for a base to close in order to repurpose a facility because they may be able to lease space. For example, a manufacturer leased space at Chanute Air Force Base in Illinois, in 1992, even though the base was not yet closed.

Classroom Discussion Questions:

  1. Has a military installation closed near you and how has it been repurposed?
  2. What good and bad effects does base closing have on the community?

OM Podcasts Now Available on SoundCloud

 Our OM Podcasts are now available on SoundCloud! You can just listen to any of the 15 at that site, and you don’t need to an account to listen. Here is the link:

https://on.soundcloud.com/b1kRJ

 

We are also planning to distribute podcasts so our listeners can subscribe in the future and listen where they already enjoy their podcasts.  More to come on that soon.

OM Podcast #15: Automation, AI, and Operations at Frito-Lay

In the latest podcast, Barry interviews Tom Rao, Senior Vice President of US Field Operations for Frito-Lay, a division of PepsiCo.  Tom and Barry discuss various operations improvements at Frito-Lay, general plans for how Frito-Lay plans to utilize AI to support the business, and how Frito-Lay is addressing the challenge around labor shortages.

 

Transcript

A Word document of this podcast will download by clicking the word Transcript above.

Instructors, assignable auto-graded exercises using this podcast are available in MyLab OM.  See our  earlier blog post with a recording of author and user Chuck Munson to learn how to find these, or contact your Pearson rep to learn more!  https://www.pearson.com/en-us/help-and-support/contact-us/find-a-rep.html

Guest Post: Leveraging Operations for Competitive Advantage in 2024

Prof. Misty Blessley, at Temple University, shares her insights with our readers monthly.

“From inventory management to materials requirement planning (MRP), for many years manufacturing leaders have viewed operations as a cost center — one that takes money off the bottom line rather than adding revenue to the top line”, writes Forbes (Jan. 22, 2024).This, in turn, has created a tendency to treat OM as a set of functional areas that must be continually optimized to reduce costs. But industry is at an inflection point. In an era of heightened customer expectations, diversified supply networks, rapidly advancing technologies, and enhanced environmental, social and governance (ESG) scrutiny, firms are challenged to consign this long-standing, cost-driven view to the past.

With the supply chain being where many of these challenges are being addressed, it is the focal point for viewing operations as a firm’s competitive advantage. By taking a more strategic approach, companies can also think outside the box of traditional OM and turn their supply chain into the center of enhanced operations performance.

Here are three questions firms must answer to achieve an advantage through their operations.

1. What does making the supply chain a center of enhanced performance look like? It means leaving behind the use of historical data in favor of taking on new technologies to gather consumer insights for driving customer satisfaction.

2. What happens when firms get strategic operations right? When consumer insights and OM are in harmony, firms do a better job at meeting customer expectations, to the benefit of increased customer loyalty (i.e., sales). The employee experience is also improved.

3. How can strategic operations be achieved? This can be done by integrating the supply chain across multiple enterprise operations in response to demand signals captured across the value chain. For example, rather than just trying to balance demand and supply to avoid a stock-out or excess inventory, companies work to balance operations to deliver the right product to the right customer at exactly the right time.

There is always pressure to control costs, but leveraging technology is the key to using the supply chain to build competitive advantage. This has the potential to positively affect the firm’s top as well as bottom lines.

Classroom Discussion Questions:
1. Chapter 11 of your text states: “The objective of supply chain management is to structure the supply chain to maximize its competitive advantage and benefits to the ultimate consumer.” How is viewing the supply chain as a revenue driver, as opposed to a cost center, in line with this objective?
2. What is the role of business analytics (Module G) in setting the stage for strategic operations in 2024?

OM in the News: JIT Makes a Retail Comeback

Retailers are reviving an old playbook to manage their inventory levels after four years of struggling to find the sweet spot of holding enough merchandise but not too much, reports The Wall Street Journal (Jan. 24, 2024). They have worked through the excess inventory that piled up on store shelves and in warehouses over the past 18 months, and are now focusing on replenishing items rather than stocking up on goods to have on hand in case of supply-chain disruptions.

The shift marks a return to the “just-in-time” inventory management strategy (our topic in Chapter 16) that many companies had employed before pandemic-driven product shortages and volatile shifts in consumer demand prompted a switch to a “just-in-case” stockpiling approach. Companies are now better able to predict shopper demand and feel they can hold leaner inventories amid moderating spending growth and fewer supply-chain disruptions. They prefer not to hold large inventories because the excess stock ties up capital, requires more space and people to manage it, and runs the risk of becoming outdated as trends change.

“Retailers have more confidence in the overall supply chain and the logistics network and the environment, and as a result, they’re saying we’re at a point now where we’re safe to go back to JIT,” says Ohio State U. Prof Terry Esper. The SCM head at Tailored Brands adds: “The ability to react to changes in demand means the company has no need for ‘safety stock’ inventory.”

Retailers such as Walmart have rolled out technology aimed at fixing forecasting tools that were broken during the pandemic as they seek to better understand what consumers are buying and more accurately predict demand. The technology is allowing merchants to have smaller, more accurate shipments than they have in the past. “We’re able to better predict lead times, we’re able to better execute review cycles, and as we do that better, we’re able to hit target inventory levels,” says Walmart’s VP for SCM.

Still, new supply-chain disruptions could prompt a different approach and bring in more excess stock. Recent attacks by Houthi rebels in Yemen on containerships have pushed companies to reroute shipments over longer distances to avoid the Suez Canal, and low water levels at the Panama Canal have slowed some deliveries.

Classroom discussion questions:
1. Why the return to JIT?
2. Will there be less volatility in supply chains from this point on?

OM in the News: Robots Are Looking Better to Detroit

United Auto Workers (UAW) members recently approved a labor contract with Ford, General Motors, and Jeep maker Stellantis that included a record 25% wage increase over 4 years and marked the sharpest labor-cost increase for the companies in recent memory. The auto makers did avoid a strike, but the longer term cost was great, reports The Wall Street Journal (Jan. 15, 2024).

Robots weld the body of a Model Y EV at a Tesla factory
The effect from the deals in Detroit quickly rippled through the industry, with Toyota, Hyundai and other nonunionized automakers increasing wages to stay competitive. The contracts were richer than Detroit had planned for, and the auto makers are strategizing ways to blunt the increased costs. Ford said the new terms would add $900 in cost per vehicle by 2028.

So the firms are looking to an old friend to help offset rising labor costs: robots. For decades, car companies increased automation inside their factories. Now, they are looking even more seriously at this approach, to address the rising labor bill and take advantage of more sophisticated technology. Competition from newcomers like Tesla, which has been more aggressive in deploying robots, is also nudging more traditional auto manufacturers in this direction.

The global auto industry is a top consumer of robots, having installed 136,000 new industrial robotic units in 2022. Often these so-called cobots work alongside workers to access hard-to-reach spots or perform tasks that are particularly physically demanding.

Dozens of new battery and EV plants in the works will also open the door to broader use of high-tech systems. It is easier and less costly to install robots in a new facility versus retrofitting an existing one. Plus, it is more streamlined to have updated systems that “speak” to each other smoothly, as opposed to popping in a new machine among older ones.

The UAW may have attained major wage increases, but the trend is making its members nervous about the prospect of machines replacing jobs. “The companies have used technology as a way to cut jobs instead of interjecting robots and technology to make our jobs easier,” says the UAW president.

There are risks to automating. Adding robots to a process for the first time can introduce quality problems. And whatever machines gain in terms of productivity can be zeroed out by the needed personnel to fix or program robots.

Classroom discussion questions:
1. Discuss the advantages and disadvantages of robotics in the auto industry.
2. What is Tesla’s edge?

OM in the News: An Inside Look at Boeing’s Outsourcing Mess

The site of this month’s midair door-plug blowout on this Boeing 737 is behind the wing, outlined in red

Long before the harrowing Alaska Airlines blowout this month, there were concerns within Boeing about the way it was building its planes. Like so many other manufacturers, Boeing was outsourcing more and more of the components.

Much modern manufacturing, of course, includes outsourcing, our topic in Chapter 2. From hot tubs to iPhones, machines are built in small pieces by different companies, then delivered to another factory for final assembly. The system has sliced costs from the process by letting production lines maximize output and eliminate waste. But the strategy also stretches oversight and adds risks, since the final product is only as good as the least-good supplier, writes The Wall Street Journal  (Jan. 13-14, 2024).

A Boeing engineer distributed a controversial report in 2001 warning of the risks of its subcontracting strategy, especially if Boeing didn’t provide sufficient on-site quality and technical support to its suppliers.  “The performance of the prime manufacturer can never exceed the capabilities of the least proficient of the suppliers. These costs do not vanish merely because the work itself is out-of-sight,” he wrote.

But Boeing doubled down on outsourcing in the 2000s with its 787, which was the first jet that was heavily designed by suppliers. To lower costs and risks of a new design, Boeing authorized dozens of suppliers to design and build major sections of the 787 (see text page 30), including mostly completed fuselage sections.

Now, Boeing is reckoning with the fallout from this strategy. Dozens of factories build key pieces of 737 and 787 models to be assembled by Boeing. One of the major subcontractors is Spirit Aerosystems, the sole supplier of the fuselages used in 737s and 787s. Spirit is heavily dependent on Boeing for revenue, and the two companies have often battled over costs and quality issues. The earlier 737 MAX grounding and pandemic sapped Spirit’s finances, and the company slashed thousands of jobs, leaving it short-handed and with inexperienced workers when demand recently bounced back.

Spirit employees said production problems are common and internal complaints about quality are ignored. In a given month, at a production rate of 2 fuselages a day, there are 10 million holes that need to be filled with some combination of bolts, fasteners and rivets. The result: a factory under pressure where workers rush to meet unrealistic quotas and where pointing out problems is discouraged if not punished. Increasingly, Spirit workers say, planes have been leaving the factory with “undetected defects.”

Classroom discussion questions:

  1. What are the advantages and disadvantages of outsourcing?
  2. What are Boeing’s options vis a vis Spirit?

OM in the News: Retailers, Rising Theft and Shrinkage

As retailers report on the busy holiday shopping season, operations managers will be trying to get more understanding into shrinkage and theft, reports The Wall Street Journal (Jan. 9, 2024). The stores are fighting a growing wave of theft, cutting into profits that were already under pressure. But theft is just one contributor to shrink, the industry term for the difference between inventory on the books and what’s physically on hand. Lost or damaged goods and inaccurate records also play a part.

Shrink is now one of the most frequently discussed topics among management at Home Depot, said the firm’s CFO, having moved onto its list of top priorities two years ago. That focus hasn’t changed even though some mitigation efforts, such as locking up certain items and using live-view parking lot cameras, are in place.

The higher shrink may partly reflect a return to prepandemic norms rather than entirely new trends in theft. Reduced visits to physical stores starting in 2020 simultaneously decreased the opportunities for theft, an effect that dissipated as shoppers stepped out of their houses again.

Dollar General’s gross profit rate, or its profit as a percentage of net sales, fell 5% last quarter, due primarily to increased inventory shrink, more markdowns and lower inventory markups. Shrink is a roughly 100-basis-point headwind for Dollar General. Dick’s Sporting Goods  expects shrink’s impact on its gross margin to be roughly 50 basis points higher in its current fiscal year compared with 2022.

Retailers have said they are responding by adding security personnel and technology, locking up goods and closing hard-hit stores. Target, which last year said that shrink was expected to cut into profitability by more than $500 million, closed nine stores, citing higher theft and safety concerns for shoppers and workers. Nike closed one of its Portland stores in 2022 amid issues with theft. Academy Sports & Outdoors is using locked shelves for certain items and outfitting some departments that have seen higher shrink, such as the baseball bat section, with sensors that indicate when people linger in an area. Some retailers, such as Costco, are less exposed to theft for reasons including that they sell larger, harder-to-steal products, and stores are laid out with one primary entrance and exit.

Classroom discussion questions:

  1. Why is this an OM issue?
  2. What would you do, as a supermarket manager, to cut shrink?

OM in the News: Disney World’s Start and Project Management

When Disneyland in Los Angeles opened in 1955, it was, in many ways, a disaster, writes The Wall Street Journal (Jan,6-7, 2024). There were rides out of service, restaurants that ran out of food, soft asphalt that consumed the heels of women’s shoes—all of it broadcast on national TV. Little wonder, then, that there was trepidation as the Walt Disney company approached the 1971 opening of the far more ambitious Walt Disney World, here in Orlando, especially as the word spread that it might not open in time. So, when Dick Nunis, the head of park operations, took control of the project, he was given carte blanche to do whatever it took to open the gates on Oct. 1st.

“There wasn’t anybody on that property who thought we were going to open on time,” said Dick Evans, one of the park’s managers on opening day. “And opening on time was critical to the company. We were at that point in debt up to our eyeballs. We’d borrowed close to $400 million to build phase one of Walt Disney World. And within a week of the time that he came on the property, the entire perspective changed. The energy level changed. He came in there like a tornado.”

Nunis, who recently died at the age of 91, fired contractors who got in the way, held meetings at 5 a.m. and put signs up all over the property that said the park would open on Oct. 1st. He made sure construction workers knew that their families were invited to the park a week before opening. He flew palm trees in on helicopters the night before the gates opened.

Not only did he understand the logistics of what it would take to hire thousands of employees, motivate construction workers and oversee the myriad details of opening a resort, he had worked closely with Walt Disney for a decade and knew how the company’s founder would have wanted it done.

Chapter 3 in our text deals with project management and the critical role of the project manager, Nunis, in this case. What does Disney World look like 62 years later? With 77,000 employees (called “cast members”) and six parks (Animal Kingdom, Epcot, Magic Kingdom, Typhoon Lagoon, Hollywood Studios, and Blizzard Beach), we see that the stakes in project management are high.

Classroom discussion questions:

  1. What are the responsibilities of a project manager?
  2. What are the 3 phases of the management of projects? (Hint: see page 62 in your text).

OM in the News: Military Supply Chain Struggles

A Norwegian factory, Kongsberg, produces a missile-defense system that can shoot down drones, helicopters and other airborne threats from 25 miles away.  Capable of launching 72 missiles into the sky at once, the Nasams system is what protects the airspace over the White House. Kongsberg, which in addition to Nasams also makes ship-based missiles and parts of F-35 fighter jets, has ramped up production to 24-hour, 7-day shifts. That still may not be enough. With the West confronting a rising number of potential threats, including Russia, Iran, and China, orders are piling up for the Nasams.  It takes two years to make one Nasams, and there is already a multiyear backlog.

Israel’s Iron Dome antimissile system intercepted rockets launched recently from the Gaza Strip

Modern weapons are hugely complex, often requiring thousands of parts, reports The Wall Street Journal (Jan. 4, 2024). Kongsberg, like most Western defense firms, designs and assembles its weapons systems but doesn’t manufacture most of the components. Over 1,500 suppliers contribute to the products. The Nasams supply chain alone consists of 1,000 companies and is built across two continents. Kongsberg states: “We are supplied by companies with their own supply chains, which in turn have their own supply chains, which have their supply chains, till it gets right down to the mine that digs up the basic resources.”

In a 2023 wargame simulation of how the U.S. would respond to a Chinese invasion of Taiwan, it was estimated America would run out of all-important long-range antiship missiles within the first week. The U.S. wouldn’t be able to replenish its stock quickly: As with the Nasams, each missile takes about two years to make.

Other missile categories have similar issues.  Lockheed Martin said it will take four years to double production of Javelin and Stinger surface-to-air missiles, twice as long as expected, as supply-chain challenges continue. Pentagon officials said the problems were widespread, with everything from chips to springs and ball bearings running short. The U.S. tried to track the global supply chains for the two missiles with the goal of finding workarounds for bottlenecks, said a pentagon leader. His conclusion was sobering: “We do not have that ability.”

The Pentagon aims to map global supply chains for 100 weapons systems in production, down to part number and country of origin. The move is intended to identify pinch points early, and mitigate them by finding alternative suppliers.

Classroom discussion questions:

  1. What is causing the supply chain problems in the defense industry?
  2. How can they be addressed?

OM Podcast #14: Feeding the World Through Complex Supply Chains

In our latest podcast, Barry speaks with F. Scott Fein, Vice President of the Northeast Region of Robinson Fresh, a company that aims to “feed the world through complex supply chains.”  They discuss cold food storage supply chains and operations, the effects of AI, sustainability, and product variety and customization.

 

 

Transcript

A Word document of this podcast will download by clicking the word Transcript above.

Instructors, assignable auto-graded exercises using this podcast are available in MyLab OM.  See our  earlier blog post with a recording of author and user Chuck Munson to learn how to find these, or contact your Pearson rep to learn more!  https://www.pearson.com/us/contact-us/find-your-rep.html