Annexure A-Covering letter Dear Respondent I am working as an Assistant Professor in PES's Modem College of Engineering -MBA Department at the University of Pune. Currently I am pursuing Doctoral Research under the guidance of Prof Dr. G.K. Shirude-Director, Naralkar Institute of Career Development and Research. The topic of my research is "A Study of supply chain management system of Auto Industries in Pune Region with reference to Passenger Car Segment. The questionnaire has been designed in such a way that it will not consume much of your precious time. Most of the questions can be answered by simply making a tick in a box. Kindly fill the questionnaire and in a way give me a helping hand towards the completion of my Research work. • This is an independent research study and participation is voluntary. Your responses will be treated as strictly confidential and the anonymity of companies and respondents is assured. • No person or firm will have access to your conq)leted questionnaire. Should you require a copy of the abbreviated report of the findings please write your name, email address or telephone number at the end of the questionnaire. I look forward to your positive response. Yours sincerely Shraddha Khoje Research Student /-f • Annexure B; Survey auestionnaire SECTION 1: GENERAL INFORMATION Company Profile 1. Name of Company 2. Address 3. Tel 4. Fax 5. Website 6. Contact person: 7. E-mail: 8. Position in conpany: No of employees: [ ] Turnover : f 9. Yearofestablishment- 10. Indicate which of the following is/are your target customer(s) and the number of years your company has been supplying this market. i. Original Equipment Manufacturers(OEM) ii. Original Equipment Suppliers(OES) iii. Automotive retail and after market iv. Other if any (Specify): 189 SECTION 2: CHALLENGES IN MANAGING SUPPLY CHAIN Up to what extent your company experiences the following supplier relationship issues. Please use the comments block for further comments/explainations. Challenging areas Tick ,If Up to what extent the challenge is? not a Please tick/circle at appropriate challenge place Lesser Extent Greater extent 1 Trust between you and your suppliers 2 3 4 5 2 Delivery of the right quality material 2 3 4 5 3 Availability of On-time delivery 2 3 4 5 4 Material Availability 2 3 4 5 5 Material lead time 2 3 4 5 6 Price/ Cost of the materials 2 3 4 5 7 Procurement lead time 2 3 4 5 8 Flexibility in supply chain 2 3 4 5 9 Financial stability of suppliers 2 3 4 5 10 capacity limitations of the suppliers 2 3 4 5 11 Poor communication between the 2 3 4 5 parties involved in supply chain 12 SuppUers do not have ISO accreditation 2 3 4 5 13 Delays in oflf-loading vessels(Due to 2 3 4 5 congestion) 14 Delays in off loading vessels (Due to 2 3 4 5 Weather condition) 15 Road Delays 2 3 4 5 16 Prohibition of downtown circulation 2 3 4 5 17 Heavy Tolls 2 3 4 5 18 Dissuasion 2 3 4 5 19 Government rules and regulations 2 3 4 5 20 Taxes and levis 2 3 4 5 190 21 Supplier's ability to JIT 1 2 3 4 5 purchasing/Delivery 22 Demand forecasting 2 3 4 5 23 Output based on customer forecasts to 2 3 4 5 plan 24 Continuous Improvement 2 3 4 5 25 Cycle times 2 3 4 5 26 Inventory levels 2 3 4 5 27 Shortage of a key material 2 3 4 5 28 Outdated Technology 2 3 4 5 29 Cost of replacing outdated technology 2 3 4 5 30 Labour problem-availability of skills 2 3 4 5 31 Capacity limitations due to customer 2 3 4 5 order fluctuations 32 Use of information system such as ERP 2 3 4 5 33 Capacity limitations due to capital 2 3 4 5 funding 34 Use of RFID Technology 2 3 4 5 35 MRP implementation at suppliers end 2 3 4 5 36 Order fluctuations 2 3 4 5 37 Cancellation of orders 2 3 4 5 38 Difficulty in meeting quality 2 3 4 5 requirements 39 Pressure by OEMs to reduce prices 2 3 4 5 40 Expectations of customers to comply 2 3 4 5 with new technology are too high 41 Need of Supply Chain Risk 1 2 3 4 5 Management 191 SECTION 3: OVERVIEW OF SUPPLY CHAIN SYSTEM 1 .How do you manage your supply chain? Tick all that apply I—'' Close partnership with suppliers I—12 Close partnership with customers Q JIT supply I—^ e-procurement Q EDI '—'^ Outsourcing '—''^ Subcontracting '—^ Plan strategically D.o Supply Chain Benchmarking I 111 Vertical integration Few suppliers Many suppliers Holding safety stock LJI5 Use of external consultants '6 Other, please specify 2. How successftxl do you think is your company in managing its supply chain in general? Not successful ^^ ^ , Somewhat _ ^ , Very Not successful _ , Successful ^ , at all successful successful Ux D^ D^ D^ D7" 192 3. Which of the following you think that your company needs to do in order to manage its supply chain better? Tick all that apply. Start Satisfied Not Improve Implementing already appropriat Close partnership with suppliers Close partnership with customers JIT supply e-procurement EDI Outsourcing Subcontracting 3PL Plan strategically Supply Chain Benchmarking Vertical integration Few suppliers Many suppliers Holding safety stock Use of external consultants Other {specify) 4. Does your company have a separate logistics department? O YES DNO 5. Does your company have a clear logistics strategic plan? O YES DNO 193 6. What types of systems are currently in use in your company to support Supply Chain Management? Custom- Standard Not in made package use Material Requirements Planning (MRP) Manufacturing Resources Planning (MRPII) Enterprise Resource Planning (ERP) Warehouse Management System (WMS) Supply Chain Management (SCM) Customer Relationships Maragement (CRM) Supplier Relationships Management (SRM) Advanced Planning System (APS) Just In Time (JIT) Theory of Constraints (TOC) E-commerce E-business Decision support / expert system Radio Frequency Identification (RFID) Electronic Data Interchange (EDI) Bar coding Other {specify) How much did you actually benefit fi-om using these systems? Not at all Little Average Greatly A lot Don't know (1) (2) (3) (4) (5) Better quality of information Better quantity of information Flexibility Reduced lead-time in production Cost saving Forecasting Resource planning Better operational efficiency Reduced inventory level More accurate costing Increased coordination between Increased coordination with Increased coordination with Increased sales 194 Better quality of information Better quantity of information Flexibility In what level your company is facing the problems below when using these systems? No Signific Little Some Serious problem ant Don't problem problem problem at all problem know (1) (2) (3) (4) (5) Resistance to change from Resources shortages e.g. no maintenance and update Skills shortages e.g. Computer illiteracy within the company Insufficient vendor support Hidden cost Integration with existing system Integration with supplier's system Integration with customer's system Other (specify) 9. What types of systems do you plan to implement in the near future (within the next 2 years)? Custom- Standard Not going made package to Material Requirements Planning (MRP) Manufacturing Resources Planning (MRPII) Enterprise Resource Planning (ERP) Warehouse Management System (WMS) Supply Chain Management (SCM) Customer Relationships Management (CRM) Supplier Relationships Management (SRM) Advanced Planning System (APS) Just In Time (JIT) Theory of Constraints (TOC) E-commerce E-business 195 Decision support / expert system Radio Frequency Identification (RFID) Electronic Data Interchange (EDI) Bar coding Other (specify) 10. How satisfied are you with the current pubUc policy regarding SCM? Somewhat Satisfied Quite satisfied Very satisfied Not at all D D; D: D. Di 196 Annexure C: Interview /discussion schedule Date: Name of the organisation: Person interviewed: Designation: 1. INTRODUCTION The introduction explains the purpose of the study and the role of the respondents. In addition, the aim is to assure the participants' confidentiality. The aim of interview schedule/discussion guide is to find out from the respondent regarding their perception about the supply chain challenges/problems. • What are the major supply chain challenges you face ? • What part of the SC are you concerned about? • Is In what part of the SC do you feel improvement is possible? • Do you follow JIT deliveries? • How many are your total number of suppliers? • How do you select supphers? How do you assess your suppliers? • What is the nature and scope of the suppUer development activities at your endr? • Are suppliers involved in the design and development processes? • What is the level of supplier innovation? How are suppliers encouraged to innovate and how is this communicated in your company? • How would you describe your relationships with your suppliers (eg traditional/partnership/collaborative)? • What quality accreditation do you expect your suppliers to have? • Do all suppliers have this accreditation? 197 • How do you handle nonconformance by suppliers (eg quality, meeting specs and delivery deadlines)? • How many shifts do you have? • How many deliveries do you have during shifts? • Do suppliers deliver during each shift? • What is your procurement poUcy? • How do you handle your demand management? • How do you forecast your demand? • What transport mode do your suppliers use - road/rail? • What are the challenges dealing with suppliers? • Does this result in increased cost of inventory in transit? • Are local components delivered via road and/or rail transport? • What are the challenges using road/rail transport (ie capacity and security)? • What type of containers are used? • Is packaging returned to suppliers? If "yes", does this act as a Kanban? • How do you handle returns to suppliers? • What type of ERP systems do you use? • How do you share data (demand and work flow data) with suppliers in the supply chain? • Do your suppliers operate on a supplier management inventory system? • Do you use EDI systems to exchange data with suppliers? • Do your suppliers recycle certain components? If so, how many and which components? • Do your suppliers remanufacture certain components? If so, how many and which components? 198 Annexure D: AutomobUe industries in India AUTOMOBILE COMPANIES IN INDIA Following is the List of Automobile Manufacturing Plants in various States of India.