The Swedish retailer dominates markets in 32 countries, and now it’s poised to conquer North America. Its battle plan: Keep making its offerings less expensive, without making them cheap. Above all else, one factor accounts for IKEA’s success: good quality at a low price. IKEA sells household items that are cheap but not cheapo, at prices that typically run 30 to 50 percent below the competition’s. While the price of other companies’ products tends to rise over time, IKEA says it has reduced its retail prices by a total of about 20 percent during the past four years. At IKEA, the process of driving down costs starts the moment a new item is conceived and continues relentlessly throughout its production run. The price of a basic Pöang chair, for example, has fallen from $149 in 2000 to $99 in 2001 to $79 today. IKEA expects the most recent price cut to increase Pöang sales by 30 to 50 percent. IKEA’s corporate mantra is “Low price with meaning.” The goal is to make things less expensive without ever making customers feel cheap. Striking that balance demands a special kind of design, manufacturing, and distribution expertise. But IKEA pulls it off in its own distinctive way: tastefully, methodically, even cheerfully, and yet somehow differently than any other company anywhere. Here’s a step-by-step guide to how IKEA designs, builds, and distributes the items that the entire world wants to buy. The Trofé mug is one of the most popular IKEA products. The story of the mug is an example of how IKEA works, from a co-worker’s bright idea through to production and sales. It is also a story about all the demands that customers place on IKEA. A low price tag is the obvious one, but other requirements include function, modern design, environmental considerations, and making sure products have been manufactured under acceptable working conditions. Both customers and co-workers must be able to rely on IKEA. Step 1. Pick a Price Product Development—A sketch for a new product? Yes, but it’s also a calculation of what that product will cost. The low price begins at the drawing board. The team behind each product consists of designers, product developers, and purchasers who get together to discuss design, materials, and suitable suppliers. Everyone contributes with their specialist knowledge. Purchasers, for example, use their contacts with suppliers all over the world via IKEA Trading Service Offices. Who can make this at the best quality for the right price at the right time? When product developers were given the task of creating a new mug over five years ago, they were told how much it should cost in the stores. In the case of Trofé, the price had to be incredibly low—five Swedish kronor! This mug had to have a real knockout price. To produce the right mug at the right price, the developers had to take into account materials, colors, and design. For example, the mug is made in green, blue, yellow, or white because these pigments cost less than other shades, such as red. Step 2. Choose a Manufacturer Suppliers and Purchasing—The task of developing products never ends. Working with suppliers, the mug was shortened and the handle changed so it stacks more efficiently, saving space for transport, warehousing, and store display—and, not least, in the customers’ cupboards at home. IKEA is always keen to banish as much air as possible from its packaging. Packages should preferably be flat for efficient transport and storage. One supplier, a factory in Romania, has worked with IKEA for 15 years. Long-term relationships help both parties to build up a huge fund of knowledge about demands and expectations. That is why products are often developed in close cooperation with suppliers. In the case of Trofé, for example, the new size has rationalized production by making better use of the space in the kiln during the firing process. That’s cost-effective and saves time. IKEA has introduced a code of conduct governing working conditions and environmental awareness among suppliers. This deals with matters such as health and safety in the workplace and forbids the use of child labor. The practical work of implementing this code of conduct is carried out by co-workers in IKEA Trading Service Offices worldwide. Many suppliers already meet the demands; others are working together with IKEA to carry out the necessary improvements. IKEA also works closely with external quality control and audit companies that check that IKEA and its suppliers live up to the requirements of the code of conduct. The low price tag is crucial to the vision IKEA has of creating a better everyday life for many people. That is why IKEA works nonstop to reduce costs. But it’s also a question of saving raw materials and, ultimately, the environment. The low-cost mug is one example of how ment of products. For example, the new mug is lighter in color—a move that cuts costs and is more environmentally friendly. The less pigment that is used, the better. The mug is also lead- and cadmium-free. Step 3. Design the Product With a price point and a manufacturer in place, IKEA once again uses internal competition to find a designer and select a design for production. The designer begins the design process by writing a brief that explains the product’s price, its function, the materials to be used, and the fabricator’s capabilities. The designer then sends the brief to IKEA’s staff designers and freelancers, and refines promising designs until settling on the one to produce. The designer wants products to be like Swiss Army knives—to get maximum functionality at minimum cost. Step 4. Ship It Distribution and logistics are the lifeblood of IKEA and important pieces of the puzzle on the road to a low price. IKEA strives to deliver the right number of goods to the right stores at the right time. It calculates the goods requirements and makes sure that deliveries are efficient. Each pallet holds 2,024 mugs, which are transported from Romania by rail, road, and sea to IKEA distribution centers around the world. Transportation does, of course, have an effect on the environment, but IKEA is working toward reducing environmental impact. Many of IKEA’s products are bulky—for example, tables and chairs. IKEA pioneered the concept of flat. The company’s eureka moment occurred in 1956, when one of IKEA’s first designers watched a customer trying to fit a table into his car. There was only one way to do it: Remove the legs. From that day forward, most IKEA products have been designed to ship disassembled, flat enough to be slipped into the cargo hatch of a station wagon or safely tied down on an auto’s roof rack. In IKEA’s innately frugal corporate culture, where waste has been declared a “deadly sin,” the flat package is also an excellent way to lower shipping costs by maximizing the use of space inside shipping containers. The company estimates transport volume would be six times greater if its items were shipped assembled. From the design studio to the warehouse floor, IKEA employees’ mantra is always the same: “We don’t want to pay to ship air.” Making things flat is an IKEA obsession. How many times can you redesign a simple fired-clay coffee mug? IKEA’s mug was redesigned three times—simply to maximize the number of them that could be stored on a pallet. Originally, only 864 mugs would fit. A redesign added a rim such as you’d find on a flowerpot, so that each pallet could hold 1,280 mugs. Yet another redesign created a shorter mug with a new handle, allowing 2,024 to squeeze onto a pallet. While the mug’s sales price has remained at 50 cents, shipping costs have been reduced by 60 percent, which is a significant savings, given that IKEA sells about 25 million of the mugs each year. Even better, the cost of production at IKEA’s Romanian factory also has fallen because the more compact mugs require less space in the kiln. When you ship 25 million cubic meters of goods all over the globe, flat-pack frugality adds up. IKEA now uses a 65 percent average fill-rate target for all the containers it ships, and it hopes to increase that to 75 percent. Meeting that goal will require further design changes and sometimes even sucking the air out of items (like IKEA’s shrink-wrapped pillows, which look like giant crackers on store shelves). And, of course, flat packing shifts the cost of product assembly to the customer, saving even more. As IKEA has shifted more of its buying from Europe to the Far East, shipping time and costs have become an even more critical concern. Last year, China tied Sweden atop IKEA’s list of supplier countries. The company has responded by creating a global network of distribution centers, most of which are near container ports and major truck and rail routes. There are 18 IKEA distribution centers worldwide—which handle about 70 percent of IKEA’s total product line—and 4 more are under construction. The other 30 percent of IKEA’s products travel directly from supplier to store. Sometimes, however, product components actually come together for the first time in the store. In the case of the Pöang chair, the cushion comes from Poland and the frame from China. The two pieces are united only when the customer pulls each one off the shelf. Step 5. Sell It IKEA sells a lot of expensive furniture, and in a traditional store this is relatively easy: Put a piece in a lush setting, let the customer fall prey to visions of wealth and comfort, then offer plenty of easy credit. But to keep prices low, IKEA needs to sell furniture and other products such as the mug without salespeople or conspicuous price reductions. The company asks customers to assemble their furniture themselves. And IKEA doesn’t want to ship it to you either. By any conventional measure, these are formidable hurdles to overcome. Yet they also explain why IKEA has worked so hard to create a separate world inside its stores—a kind of theme park masquerading as a furniture outlet—where normal rules and expectations don’t apply. The Trofé mugs arrive at IKEA stores packed on pallets. Any transportation packaging is collected for recycling. Price tags have already been placed on the mugs at the suppliers. In-store display is important. It’s not just a question of displaying mugs and other products. It’s also about providing inspiration for smart interior solutions. Customers contribute to the low prices at IKEA by selecting and collecting the products from the self-serve area, taking them home, and using the instructions enclosed to assemble them. Many will have already chosen the products from the IKEA catalog, of which 110 million copies are printed in 34 different language versions. When you walk through the door of an IKEA store, you enter a meticulously constructed virtual Sweden. The first thing you encounter is a company-sponsored child-care facility. Hungry? Have some of those Swedish meatballs and lingonberries. The layout of an IKEA store guides shoppers in a predetermined path past several realistic model homes, which convey an eerily lived-in impression but are open for customers to sit in. Information kiosks provide advice on home decor. Color-coordinated cards offer plenty of suggestions on offbeat uses for products. But the emphasis is always on price. Low-priced products that IKEA calls BTIs (“breathtaking items”) are often perched on risers, framed by a huge yellow price tag. Nearby, shoppers will find other products—pricier, more design-oriented—as substitutes for the BTI. The model homes suggest cheerful young people throwing dinner parties in hallways, using mismatched office chairs and narrow side tables. These aren’t the aspirational images you’ll find at Pottery Barn or Crate & Barrel. These are people who are living well in modest circumstances—frugal folks who know the value of a comfortable place to sit. IKEA says its biggest selling point is the price tag, but it can’t hurt that getting through one of IKEA’s huge stores takes a lot of time. The layout is blatantly manipulative— though in a friendly, knowing way, not unlike at Disneyland—but when customers finally arrive at the checkout counter, they’ve had plenty of time to fully consider their purchases. IKEA products broadcast an ethos for living in the modern world: Don’t buy an ugly pitcher if you can get a stylish one for the same price. If you organize your plastic bags, you’ll feel more in control of your life. It’s leftbrain logic applied to the right-brain art of living well. And if happiness involves dragging a cumbersome flat package off the shelf, standing in line at the checkout, hauling the box home, and spending hours assembling a kitchen cabinet, well, 260 million customers a year are willing to make that trade-off. And, of course, next year it will be even cheaper. Questions 1. What are IKEA”s competitive priorities? 2. Describe IKEA’s process for developing a new product. 3. What are additional features of the IKEA concept (beyond their design process) that contribute to creating exceptional value for the customer? 4. What would be important criteria for selecting a site for an IKEA store?
> Why is it that reducing moves, delays, and storages in a manufacturing process is a good thing? Can they be completed eliminated?
> What is meant by manufacturing process flow?
> How does the production volume affect break-even analysis?
> It has been noted that during World War II Germany made a critical mistake by having its formidable Tiger tanks produced by locomotive manufacturers, while American car manufacturers produced the less formidable U.S. Sherman tank. Use the product-proces
> In what way might the first-come, first-served rule be unfair to the customer waiting for service in a bank or hospital?
> Lambda Computer Products competed for and won a contract to produce two prototype units of a new type of computer that is based on laser optics rather than on electronic binary bits. The first unit produced by Lambda took 5,000 hours to produce and requi
> Logistics Consultants Inc. (LCI) provides various logistics analysis services to other firms, including facility location decisions. They have just completed a project for a major customer, but on the eve of their presentation they discovered a computer
> Have you driven any car lately? Try not to think of the insurance claims settlement process while you drive! How would you reengineer your insurance company’s claims process?
> Johnson Industries received a contract to develop and produce four high-intensity long distance receiver/transmitters for cellular telephones. The first took 2,000 labor hours and $39,000 worth of purchased and manufactured parts; the second took 1,500 l
> Management may choose to build up capacity in anticipation of demand or in response to developing demand. Cite the advantages and disadvantages of both approaches.
> Lazer Technologies Inc. (LTI) has produced a total of 20 high-power laser systems that could be used to destroy any approaching enemy missiles or aircraft. The 20 units have been produced, funded in part as private research within the research and develo
> You’ve just completed a pilot run of 10 units of a major product and found the processing time for each unit was as follows: Unit Number Time (hours) 1 ………………………………………………. 970 2 ………………………………………………. 640 3 …………………
> United Research Associates (URA) had received a contract to produce two units of a new cruise missile guidance control. The first unit took 4,000 hours to complete and cost $30,000 in materials and equipment usage. The second took 3,200 hours and cost $2
> Discuss the graphic presentations in Exhibit 4.11. Are there any other graphic outputs you would like to see if you were project manager? | Sample of Graphic Project Reports exhibit 4.11 A.Gantt Chart for Single Activities B. Total Program Cost Bre
> Honda Motor Company has discovered a problem in the exhaust system of one of its automobile lines and has voluntarily agreed to make the necessary modifications to conform with government safety requirements. Standard procedure is for t
> Omega Technology is starting production of a new supercomputer for use in large research universities. They have just completed the first unit, which took 120 man-hours to produce. Based on their experience, they estimate their learning percentage to b
> Company Z is just starting to make a brand new product they have made before. They have completed two units so far. The first unit took 12 hours to complete and the next unit took 11 hours. Based only on this information, what would be the estimate of
> Firm A typically sees a learning percentage of 85% in their processes. Firm B has a learning percentage of 80%. Which firm has the faster learning rate?
> Think about the registration process at your university. Develop a flow chart to understand it. How would you radically redesign this process?
> Distinguish between known mathematical distributions and empirical distributions.What information is needed to simulate using a known mathematical distribution?
> Santa Cruz Bottling is a manufacturer of organic soft drinks on the coast of central California. Its products are enjoying a growing reputation and increased demand throughout the American Southwest. Because of the high cost of transporting soft drinks,
> A distributor of large appliances needs to determine the order quantities and reorder points for the various products it carries. The following data refer to a specific refrigerator in its product line. Consider an even daily demand and a 365-day year.
> How do you determine the idle-time percentage from a given assembly-line balance?
> A company has just tested the skills of two applicants for the same job. They found that applicant A had a higher learning rate than applicant B. Should they definitely higher applicant A?
> True or False: The only learning for an organization comes from the individual learning of its employees.
> The purpose of value analysis/value engineering is to _____________
> The first step in developing a house of quality is to develop a list of __________________.
> Designing products for aesthetics and with the user in mind is generally called what?
> A process that emphasizes cross-functional integration and concurrent development of a product and its associated processes is known as _________________________.
> In discussing characteristics of efficient plants, Goodson, developer of “Rapid Plant Assessments”, suggests that numerous forklifts are a sign of poor space utilization. What do you think is behind this observation?
> Match the following product types to the appropriate product development description. Technology-push A. Entail unusually large uncertainties about the technology or market. The development process takes steps to address those uncertainties. produc
> The following chart is a partial house of quality for a golf country club. Provide an importance weighting from your perspective (or that of a golfing friend) in the unshaded areas. If you can, using the QFD approach, compare it to a club where you or yo
> Pick a product and list issues that need to be considered in its design and manufacture. The product can be something like a stereo, cell phone, desk, or kitchen appliance. Consider the functional and aesthetic aspects of design as well as the important
> After graduation, you decide to go into a partnership in an office supply store that has existed for a number of years. Walking through the store and stockrooms, you find a great discrepancy in service levels. Some spaces and bins for items are completel
> DM Office Products (DMOP) is a wholesale supplier of office products with one facility in Pennsylvania. It has decided to build a new distribution warehouse in the state of New York to help serve the growing demand in that market. It has four major custo
> Perot Corporation is developing a new CPU chip based on a new type of technology. Its new chip, the Patay2 chip, will take two years to develop. However, because other chip manufacturers will be able to copy the technology, it will have a market life of
> What are the pros and cons of starting a simulation with the system empty? With the system in equilibrium?
> Which industry will typically have a faster learning rate: a repetitive electronics manufacturer or a manufacturer of large complex products such as a shipbuilder?
> Tuff Wheels was getting ready to start its development project for a new product to be added to its small motorized vehicle line for children. The new product is called the Kiddy Dozer. It will look like a miniature bulldozer, complete with caterpillar t
> Discuss design-based incrementalism, which is frequent product redesign throughout the product’s life. What are the pros and cons of this idea?
> What does it take to be a good consultant? Is this a career for you?
> How does the QFD approach help? What are some limitations of this approach?
> Describe the generic product development process described in this chapter. How does this process change for technology push products?
> Coca-Cola is a well-established consumer products company with a strong position in the global market. The sales of their core soda products have remained relatively stable for decades, yet the company has continued to grow and has remained extremely pr
> What factors must be traded off in the product development process before introducing a new product?
> What does an inverted triangle represent in a value stream map?
> Do the concepts of complexity and divergence apply to an online sales company such as Dell Computer?
> A small manufacturing facility is being planned that will feed parts to three heavy manufacturing facilities. The locations of the current plants with their coordinates and volume requirements are given in the following table. Use the centroid method t
> Discuss the product design philosophy behind industrial design and design for manufacture and assembly. Which one do you think is more important in a customer-focused product development?
> What methods are used to increment time in a simulation model? How do they work?
> In value stream mapping, what does an arrow in the shape of a lightning bolt mean?
> Would a warm paraffin hand treatment during your dental cleaning or dental treatment put you at ease and make the process more bearable? That is the idea behind the new “dental spa” services opening in major cities throughout the United States. Beyond ca
> Which type of system is likely to have a faster learning rate – one with primarily highly automated equipment or one that is very labor intensive?
> “Timbuk2 is more than a bag. It’s more than a brand. Timbuk2 is a bond. To its owner, a Timbuk2 bag is a dependable, everyday companion. We see fierce, emotional attachments form between Timbuk2 customers and their bags all the time. A well-worn Timbuk2
> What are the two main competitive dimensions related to product delivery?
> What is the term used to describe product attributes that attract certain customers and can be used to form the competitive position of a firm?
> Relative to the behavioral science discussion, what practical advice do you have for a hotel manager to enhance the ending of a guest's stay in the hotel?
> How often should a company develop and refine the operations and supply chain strategy.
> What is the term used to describe individuals or organizations that are influenced by the actions of a firm?
> Sycamore Plastics (SP) is a manufacturer of polyethylene plastic pellets used as a raw material by manufacturers of plastic goods around the U.S. SP currently operates four manufacturing centers in Philadelphia, PA; Atlanta, GA; St. Louis, MO; and Salt L
> A firm’s strategy should describe how it intends to create and sustain value for what entities?
> What is the term used to refer to the flow of work through a hospital?
> Shell Oil Company’s motto “People, Planet and Profit” is a real-world implementation of what OSCM concept?
> A fast-food restaurant serves hamburgers, cheeseburgers, and chicken sandwiches. The restaurant counts a cheeseburger as equivalent to 1.25 hamburgers and chicken sandwiches as 0.8 hamburger. Current employment is five full-time employees who each work a
> The following table represents a plan for a project: Construct the appropriate network diagram. Indicate the critical path. What is the expected completion time for the project? You can accomplish any one of the following at an additional cost of $1,50
> A parcel delivery company delivered 103,000 packages last year, when its average employment was 84 drivers. This year the firm handled 112,000 deliveries with 96 drivers. What was the percentage change in productivity over the two years?
> A retail store had sales of $45,000 in April and $56,000 in May. The store employs eight full-time workers who work a 40-hour week. In April the store also had seven part-time workers at 10 hours per week, and in May the store had nine part-timers at 15
> Jack Simpson, contract negotiator for Nebula Airframe Company, is currently involved in bidding on a follow-up government contract. In gathering cost data from the first three units, which Nebula produced under a research and development contract, he fou
> Sarah’s Muffler Shop has one standard muffler that fits a large variety of cars. Sarah wishes to establish a reorder point system to manage inventory of this standard muffler. Use the following information to determine the best order si
> An electronics company makes communications devices for military contracts. The company just completed two contracts. The navy contract was for 2,300 devices and took 25 workers two weeks (40 hours per week) to complete. The army contract was for 5,500 d
> Two types of cars (Deluxe and Limited) were produced by a car manufacturer last year. Quantities sold, price per unit, and labor hours follow. What is the labor productivity for each car? Explain the problem(s) associated with the labor productivity.
> Live Trap Corporation received the data below for its rodent cage production unit. Find the total productivity? Output Input 50,000 cages Production time 620 labor hours Sales price: $3.50 per unit Wages $7.50 per hour Raw materials (total cost)
> A general rule of designing hospital layouts is to separate patient/visitor flow from what?
> Logistics accounts for about what percent of the U.S. gross domestic product?
> What is the term used to describe the assessment of the probability of a negative event against the aggregate severity of the related loss?
> Match the following common risks with the appropriate mitigation strategy. Country risks A. Detailed tracking, alternate suppliers B. Careful selection and monitoring of suppliers C. Contingency planning, insurance D. Good legal advice, compliance E
> Risks caused by natural or manmade disasters, and therefore impossible to reliably predict, called?
> What is defined as the likelihood of disruption that would impact the ability of a company to continuously supply products or services?
> Must you use a computer to get good information from a simulation? Explain.
> In implementing supply chain strategy, a firm must minimize its total cost without compromising the needs of what group of people?
> University Drug Pharmaceuticals orders its antibiotics every two weeks (14 days) when a salesperson visits from one of the pharmaceutical companies. Tetracycline is one of its most prescribed antibiotics, with an average daily demand of 2,000 capsules. T
> What is the diagram that shows how a company’s strategy is delivered by a set of supporting activities?
> What are the two characteristics of a product or service that define quality?
> How do facility location decisions differ for service facilities and manufacturing plants?
> In hospitals, dashboards are often used to display performance measures on a routine basis. What type of dashboard tracks metrics such as mortality rate, quality improvement, and readmission rates?
> Ray’s Satellite Emporium wishes to determine the best order size for its best-selling satellite dish (Model TS111). Ray has estimated the annual demand for this model at 1,000 units. His cost to carry one unit is $100 per year per unit, and he has estima
> Explain how a non-bottleneck can become a bottleneck.
> Most manufacturing firms try to balance capacity for their production sequences. Some believe that this is an invalid strategy. Explain why balancing capacity does not work.
> The following list of jobs in a critical department includes estimates of their required times. a. Use the shortest operation time rule to schedule these jobs. What is the schedule? What is the mean flow time? b. The boss does not like the schedule in p
> Christine has three cars that must be overhauled by her ace mechanic, Megan. Given the following data about the cars, use the least slack per remaining operation to determine Megan’s scheduling priority for each car. Customer Pick
> A local restaurant is concerned about their ability to provide quality service as they continue to grow and attract more customers. They have collected data from Friday and Saturday nights, their busiest time of the week. During these time periods abou
> The MediQuick lab has three lab technicians available to process blood samples and three jobs that need to be assigned. Each technician can do only one job. The following table represents the lab’s estimate (in dollars) of what it will
> The following table gives the operation times and due dates for five jobs that are to be processed on a machine. Assign the jobs according to the shortest operation time and calculate the mean flow time. Processing Due Date Job Time (Days Hence) 10
> The following wait staff members are needed at a restaurant. Use the first-hour principle to generate a personnel schedule. Assume a four-hour shift. Period 11 А.М. Noon 1 P.м. 2 P.м. 3 Р.М. 4 Р.М. 5 Р.М. 6 Р.М. 7 Р.М. 8 Р.М. 9 Р.М. Requirements 4 8
> Are service operations with a high degree of customer contact more or less difficult to control than those with a low degree of customer contact?
> A hotel has to schedule its receptionists according to hourly loads. Management has identified the number of receptionists needed to meet the hourly requirement, which changes from day to day. Assume each receptionist works a four-hour shift. Given the f
> Lakeside Bakery bakes fresh pies every morning. The daily demand for its apple pies is a random variable with (discrete) distribution, based on past experience, given by Each apple pie costs the bakery $6.75 to make and is sold for $17.99. Unsold apple
> The periodic inspection and repair of equipment designed to keep the equipment reliable, thus eliminating unplanned downtime due to malfunctions is called _______________________.
> The following matrix contains the costs (in dollars) associated with assigning Jobs A, B, C, D, and E to Machines 1, 2, 3, 4, and 5. Assign jobs to machines to minimize costs. Machines Jobs 1 2 3 4 5 A 6 11 12 3 10 B 5. 12 10 9 C 7 14 13 8 12 D. 4 1
> Joe has achieved a position of some power in the institution in which he currently resides and works. In fact, things have gone so well that he has decided to divide the day-to-day operations of his business activities among four trusted subordinates: Bi