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Reverse Logistics Transformation
 Case Study at Cisco



Mudit Agarwal, Solution Architect,
Reverse Logistics, Cisco



    © 2006 Cisco Systems, Inc. All rights reserved.   1
Introduction

                                                    Focus Area

Agenda                                              Approach

                                                    Results

                                                    Closing


  © 2006 Cisco Systems, Inc. All rights reserved.
Introduction: Presenter
                      12 Years of Industry Experience, last 3 and half
                      years at Cisco




                      Worked in different companies from small start-up
                      to top fortune 100 companies




                      Currently working as Solution Architect, World-
                      Wide Reverse Logistics, Cisco




  © 2006 Cisco Systems, Inc. All rights reserved.
Introduction: Company




                                          London
                     Ottawa, Canada                                        Amsterdam
 San Jose, CA                    Boxborough, MA
                                                                            Tel Aviv           Shanghai
                                             Herndon, VA
         Richardson, TX                     Raleigh, NC
                                                                              Dubai
                                                                                   Bangalore     Singapore
  67,000 employees in 140 countries
  300+ office locations
                                                                                                          Sydney
  Headquarters:
  1/3 Engineering/IT, 1/3 Sales, 1/6 Service, 1/6 Others


EBC       © 2006 Cisco Systems, Inc. All rights reserved.
            2008                                            Cisco Public                                           4
Cisco at a Glance
Vision: Changing the way we work, live, play and learn




 Worldwide leader in networking                          10 consecutive years on Fortune Magazine‟s
  for the Internet                                         “Best Companies to Work For” list
 Founded in 1984                                         130+ acquisitions
 $110B Market Cap (Jan „09)                              85+% of Cisco Systems products are
 $29 B cash and investments                               distributed via channels

 More than $5 B/year in R&D                              Business Week valued Cisco‟s brand at
                                                           US$19.1 billion and ranked in top 20 WW


       © 2006 Cisco Systems, Inc. All rights reserved.
Innovation in Multiple Manifestations

                    New Business Model                 New Market
                                                       Unified
                    Linksys
                                                       Communications



                    New Product                        New Customer
                    or Service                         Experience
                                                       Network Advanced
                    IP Telephony
                                                       Services



                    New Process                        New Technology
                    Business Councils                  CRS-1/IOX



                    New Education
                    Engine                             New Channel
                                                       E-Commerce
                    Networking Academies


     © 2006 Cisco Systems, Inc. All rights reserved.
2008 Ranking: AMR Research—Top 25 Supply Chains
                                           2007                             2008
                                   1                  Apple     14       Best Buy
                                   2                  Nokia     15         Nike
                                   3                   Dell     16     SonyEricsson
                                   4       Proctor & Gamble     17      Walt Disney
                                   5                   IBM      18   Hewlett-Packard
                                   6                 Wal-Mart   19 Johnson & Johnson

                                   7                  Toyota    20    Schlumberger
                                  8                   Cisco     21   Texas Instruments
                                  9
                                  9                  Samsung    22   Lockheed Martin
                                 1
                                 10         Anheuser Busch      23   Johnson Controls
                                 0
                                 11                  PepsiCo
                                                       Cisco    24     Royal Ahold
                                  12                  Tesco     25 Publix Super Markets

                                  13                  Coke
                                  Source: AMR Research, 2008
   © 2006 Cisco Systems, Inc. All rights reserved.
© 2006 Cisco Systems, Inc. All rights reserved.
Introduction

                                                    Focus Area

Agenda                                              Approach

                                                    Results

                                                    Closing


  © 2006 Cisco Systems, Inc. All rights reserved.
What is Reverse Logistics
 Recovering Cisco‟s products back from Customer/
  Distributor, and redeploying them in the way that brings
  the best value to Cisco
 Create a consistent, scalable, global end-to-end
  process and system for inbound logistics and receiving
  through disposition and fulfillment




   © 2006 Cisco Systems, Inc. All rights reserved.
Reverse Logistics Vision


   “Deliver a globally consistent, scalable, world class,
  end-to-end business solution by unlocking value from
  Product Returns aiming to Optimize net cash
  contribution, Reduce transaction cost, Improve
  customer satisfaction, and Promote corporate
  citizenship”.




  © 2006 Cisco Systems, Inc. All rights reserved.
Drivers

 Lower Product Return Rate after booking
 Brand Protection / Gray Market Risk
 Value Recovery Opportunities
 Building new Customer Base




   © 2006 Cisco Systems, Inc. All rights reserved.
Cisco’s Complex Supply Chain




Hybrid                          Wide range              Most           Breadth of   Acquisition
Production                      of Products             Products Are   Customers    Integration
Model                                                   Configured                  (131 to date)
(95%                                                    to Order
Outsourced)




      © 2006 Cisco Systems, Inc. All rights reserved.
Introduction

                                                    Focus Area

Agenda                                              Approach

                                                    Results

                                                    Closing


  © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Scale

      30,000 Units received each week

      22,000,000 Lbs of material recycled
      annually

      $100,000,000 Net Contribution
      annually

Note: These numbers exclude products from consumer acquisitions‟
 like Linksys

      © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Process Verticals
                                           Customer Product Returns Management,
Inbound Logistics                          Management of product returns in transit to
                                           receiving location – Inbound

Receiving &                                On-dock receipt to put away as per disposition
Disposition                                instructions

Express                                    Repair order management, Express Test NPI
Screening &                                process, Shop floor control set up, DGI to FGI
                                           conversion
Testing

Inventory                                  Managing DGI/ FGI inventory, Management of
Management                                 Purge/Scrap process

Order                                      Point of receipt of order to point of report pick
Management

Order
                                           Report pick to actual ship confirm
Fulfillment


Outbound                                   Management of refurbished product shipment from
                                           the supplier location in transit to customer location -
Logistics                                  Outbound


    © 2006 Cisco Systems, Inc. All rights reserved.
Inbound Logistics




 •   Follow-up with customers on RMA‟s
 •   Label printing by the customer
 •   Pick-up materials from Customer location
 •   Provide visibility for on Dock receipt to close the return


       © 2006 Cisco Systems, Inc. All rights reserved.
Receiving & Disposition




 •   Receiving against a valid RMA
 •   Re-routing Failure Analysis RMA
 •   Apply disposition rules
 •   Manage discrepancy
 •   Provide customer credit


      © 2006 Cisco Systems, Inc. All rights reserved.
Inventory Management




 •   Cycle count management
 •   Increment stock based on Receipts – DGI and FGI
 •   Inventory synchronization
 •   Decrement stock through Scrap & Recycling


      © 2006 Cisco Systems, Inc. All rights reserved.
Order Management




 •   Demand list management
 •   Order Management
 •   Picking and Packing
 •   Inventory updates / decrement


      © 2006 Cisco Systems, Inc. All rights reserved.
Order Fulfillment




 •   Tax , Customs and Legal compliance
 •   Packaging
 •   Shipping
 •   Integration with outbound logistics



      © 2006 Cisco Systems, Inc. All rights reserved.
Outbound Logistics




  •   Select a transport provider
  •   Ship the product
  •   Tracking of outbound logistics


      © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Reverse Supply Chain
                                   Distributor              Reseller               End Customer
Manufacturing




                                          Service
                                          Provider




 Cisco Reverse                                                         Remarketing
 Logistics Partner                                        Recycle
                                                            Cisco




                                                                         Service              Repair

        © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Architecture Direction
                                  RMA
                                 Source
                                 System
                                                   ERP System                                     New Acquisition


          RMA                    PickList                     Like Part             Return to „A‟ Stock
 Cisco




                                                                                                                 Other Services
          Open RMA Sync                                      RMA Cancel              X-Dock Part List


                                     Product Data                         SN Data
                                                                                                          Alt Part




                                                 Service Gateway


             Receive product                           Master Data              Inventory
                                                       (PID,SN etc.)            Management
Partner




             Ship product
                                                                                                                           New Partner
                                                                                Other Capabilities                         (Acquisition
             Recycle                                   Disposition
                                                                                                                           Integration)


           © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Reverse Logistics Interactions

                                                                      RMA /
                                                                      Return tool




                                                        Reverse
                                                        Logistics
                                                        Partner                     Receipt (2)




                                                                                                     Cisco
Customer
                                                                                                  (Oracle ERP)
                                                           Ship (3)




                                                            Cisco Internal Customers


      © 2006 Cisco Systems, Inc. All rights reserved.
Approach: Challenges/ Gaps

 Implementation Challenges
   1. Short Time To Market
   2. Evolving Business Model
   3. Unavailability of Out Of Box Functionality in Oracle modules
   4. New Reverse Logistics Partner On-boarding

 Gaps in Oracle functionality
   1. Like Part Processing
   2. Pro-Active Asset Recovery Functionality
   3. Business Rules Driven Supply Demand match engine




   © 2006 Cisco Systems, Inc. All rights reserved.
Introduction

                                                    Focus Area

Agenda                                              Approach

                                                    Results

                                                    Closing


  © 2006 Cisco Systems, Inc. All rights reserved.
Solution Benefits

 Bring new customer into Cisco
 Recycling – Green Initiative
 Improved Process Efficiency
 Reduced Transaction Cost By ~ 30%
 Enhanced Customer Experience
 Improved Process for Product Reuse




     © 2006 Cisco Systems, Inc. All rights reserved.
Cost Center to Profit Center


          3 Year Trend Analysis
                                                                   $157M
$160M         Value Recovery and Net Contribution
$140M

$120M
                                                           $97M
$100M

$80M

$60M                   $49M
$40M

$20M

 $0M
                    FY06                                  FY07    FY08




        © 2006 Cisco Systems, Inc. All rights reserved.
© 2006 Cisco Systems, Inc. All rights reserved.
Introduction

                                                    Focus Area

Agenda                                              Approach

                                                    Results

                                                    Closing


  © 2006 Cisco Systems, Inc. All rights reserved.
Closing: Recap

 Took about 18 months to complete this project
 Built end to end Cisco‟s Reverse Logistics Supply
  Chain
 On-boarded new partner
 Services based Architecture
 Converted Cost Center to a Profit Center




   © 2006 Cisco Systems, Inc. All rights reserved.
Q&A



Mudit Agarwal
Email: Mudit@cisco.com



   © 2006 Cisco Systems, Inc. All rights reserved.

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Cisco Case Study Reverse Logistics Transformation (Interlog)

  • 1. Reverse Logistics Transformation Case Study at Cisco Mudit Agarwal, Solution Architect, Reverse Logistics, Cisco © 2006 Cisco Systems, Inc. All rights reserved. 1
  • 2. Introduction Focus Area Agenda Approach Results Closing © 2006 Cisco Systems, Inc. All rights reserved.
  • 3. Introduction: Presenter 12 Years of Industry Experience, last 3 and half years at Cisco Worked in different companies from small start-up to top fortune 100 companies Currently working as Solution Architect, World- Wide Reverse Logistics, Cisco © 2006 Cisco Systems, Inc. All rights reserved.
  • 4. Introduction: Company London Ottawa, Canada Amsterdam San Jose, CA Boxborough, MA Tel Aviv Shanghai Herndon, VA Richardson, TX Raleigh, NC Dubai Bangalore Singapore  67,000 employees in 140 countries  300+ office locations Sydney  Headquarters:  1/3 Engineering/IT, 1/3 Sales, 1/6 Service, 1/6 Others EBC © 2006 Cisco Systems, Inc. All rights reserved. 2008 Cisco Public 4
  • 5. Cisco at a Glance Vision: Changing the way we work, live, play and learn  Worldwide leader in networking  10 consecutive years on Fortune Magazine‟s for the Internet “Best Companies to Work For” list  Founded in 1984  130+ acquisitions  $110B Market Cap (Jan „09)  85+% of Cisco Systems products are  $29 B cash and investments distributed via channels  More than $5 B/year in R&D  Business Week valued Cisco‟s brand at US$19.1 billion and ranked in top 20 WW © 2006 Cisco Systems, Inc. All rights reserved.
  • 6. Innovation in Multiple Manifestations New Business Model New Market Unified Linksys Communications New Product New Customer or Service Experience Network Advanced IP Telephony Services New Process New Technology Business Councils CRS-1/IOX New Education Engine New Channel E-Commerce Networking Academies © 2006 Cisco Systems, Inc. All rights reserved.
  • 7. 2008 Ranking: AMR Research—Top 25 Supply Chains 2007 2008 1 Apple 14 Best Buy 2 Nokia 15 Nike 3 Dell 16 SonyEricsson 4 Proctor & Gamble 17 Walt Disney 5 IBM 18 Hewlett-Packard 6 Wal-Mart 19 Johnson & Johnson 7 Toyota 20 Schlumberger 8 Cisco 21 Texas Instruments 9 9 Samsung 22 Lockheed Martin 1 10 Anheuser Busch 23 Johnson Controls 0 11 PepsiCo Cisco 24 Royal Ahold 12 Tesco 25 Publix Super Markets 13 Coke Source: AMR Research, 2008 © 2006 Cisco Systems, Inc. All rights reserved.
  • 8. © 2006 Cisco Systems, Inc. All rights reserved.
  • 9. Introduction Focus Area Agenda Approach Results Closing © 2006 Cisco Systems, Inc. All rights reserved.
  • 10. What is Reverse Logistics  Recovering Cisco‟s products back from Customer/ Distributor, and redeploying them in the way that brings the best value to Cisco  Create a consistent, scalable, global end-to-end process and system for inbound logistics and receiving through disposition and fulfillment © 2006 Cisco Systems, Inc. All rights reserved.
  • 11. Reverse Logistics Vision “Deliver a globally consistent, scalable, world class, end-to-end business solution by unlocking value from Product Returns aiming to Optimize net cash contribution, Reduce transaction cost, Improve customer satisfaction, and Promote corporate citizenship”. © 2006 Cisco Systems, Inc. All rights reserved.
  • 12. Drivers  Lower Product Return Rate after booking  Brand Protection / Gray Market Risk  Value Recovery Opportunities  Building new Customer Base © 2006 Cisco Systems, Inc. All rights reserved.
  • 13. Cisco’s Complex Supply Chain Hybrid Wide range Most Breadth of Acquisition Production of Products Products Are Customers Integration Model Configured (131 to date) (95% to Order Outsourced) © 2006 Cisco Systems, Inc. All rights reserved.
  • 14. Introduction Focus Area Agenda Approach Results Closing © 2006 Cisco Systems, Inc. All rights reserved.
  • 15. Approach: Scale 30,000 Units received each week 22,000,000 Lbs of material recycled annually $100,000,000 Net Contribution annually Note: These numbers exclude products from consumer acquisitions‟ like Linksys © 2006 Cisco Systems, Inc. All rights reserved.
  • 16. Approach: Process Verticals Customer Product Returns Management, Inbound Logistics Management of product returns in transit to receiving location – Inbound Receiving & On-dock receipt to put away as per disposition Disposition instructions Express Repair order management, Express Test NPI Screening & process, Shop floor control set up, DGI to FGI conversion Testing Inventory Managing DGI/ FGI inventory, Management of Management Purge/Scrap process Order Point of receipt of order to point of report pick Management Order Report pick to actual ship confirm Fulfillment Outbound Management of refurbished product shipment from the supplier location in transit to customer location - Logistics Outbound © 2006 Cisco Systems, Inc. All rights reserved.
  • 17. Inbound Logistics • Follow-up with customers on RMA‟s • Label printing by the customer • Pick-up materials from Customer location • Provide visibility for on Dock receipt to close the return © 2006 Cisco Systems, Inc. All rights reserved.
  • 18. Receiving & Disposition • Receiving against a valid RMA • Re-routing Failure Analysis RMA • Apply disposition rules • Manage discrepancy • Provide customer credit © 2006 Cisco Systems, Inc. All rights reserved.
  • 19. Inventory Management • Cycle count management • Increment stock based on Receipts – DGI and FGI • Inventory synchronization • Decrement stock through Scrap & Recycling © 2006 Cisco Systems, Inc. All rights reserved.
  • 20. Order Management • Demand list management • Order Management • Picking and Packing • Inventory updates / decrement © 2006 Cisco Systems, Inc. All rights reserved.
  • 21. Order Fulfillment • Tax , Customs and Legal compliance • Packaging • Shipping • Integration with outbound logistics © 2006 Cisco Systems, Inc. All rights reserved.
  • 22. Outbound Logistics • Select a transport provider • Ship the product • Tracking of outbound logistics © 2006 Cisco Systems, Inc. All rights reserved.
  • 23. Approach: Reverse Supply Chain Distributor Reseller End Customer Manufacturing Service Provider Cisco Reverse Remarketing Logistics Partner Recycle Cisco Service Repair © 2006 Cisco Systems, Inc. All rights reserved.
  • 24. Approach: Architecture Direction RMA Source System ERP System New Acquisition RMA PickList Like Part Return to „A‟ Stock Cisco Other Services Open RMA Sync RMA Cancel X-Dock Part List Product Data SN Data Alt Part Service Gateway Receive product Master Data Inventory (PID,SN etc.) Management Partner Ship product New Partner Other Capabilities (Acquisition Recycle Disposition Integration) © 2006 Cisco Systems, Inc. All rights reserved.
  • 25. Approach: Reverse Logistics Interactions RMA / Return tool Reverse Logistics Partner Receipt (2) Cisco Customer (Oracle ERP) Ship (3) Cisco Internal Customers © 2006 Cisco Systems, Inc. All rights reserved.
  • 26. Approach: Challenges/ Gaps  Implementation Challenges 1. Short Time To Market 2. Evolving Business Model 3. Unavailability of Out Of Box Functionality in Oracle modules 4. New Reverse Logistics Partner On-boarding  Gaps in Oracle functionality 1. Like Part Processing 2. Pro-Active Asset Recovery Functionality 3. Business Rules Driven Supply Demand match engine © 2006 Cisco Systems, Inc. All rights reserved.
  • 27. Introduction Focus Area Agenda Approach Results Closing © 2006 Cisco Systems, Inc. All rights reserved.
  • 28. Solution Benefits  Bring new customer into Cisco  Recycling – Green Initiative  Improved Process Efficiency  Reduced Transaction Cost By ~ 30%  Enhanced Customer Experience  Improved Process for Product Reuse © 2006 Cisco Systems, Inc. All rights reserved.
  • 29. Cost Center to Profit Center 3 Year Trend Analysis $157M $160M Value Recovery and Net Contribution $140M $120M $97M $100M $80M $60M $49M $40M $20M $0M FY06 FY07 FY08 © 2006 Cisco Systems, Inc. All rights reserved.
  • 30. © 2006 Cisco Systems, Inc. All rights reserved.
  • 31. Introduction Focus Area Agenda Approach Results Closing © 2006 Cisco Systems, Inc. All rights reserved.
  • 32. Closing: Recap  Took about 18 months to complete this project  Built end to end Cisco‟s Reverse Logistics Supply Chain  On-boarded new partner  Services based Architecture  Converted Cost Center to a Profit Center © 2006 Cisco Systems, Inc. All rights reserved.
  • 33. Q&A Mudit Agarwal Email: Mudit@cisco.com © 2006 Cisco Systems, Inc. All rights reserved.