Paul R. Murphy Jr. I A. Michael Knemeyer
Contemporary Logistics
TWELFTH EDITION C
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Twelfth Edition
Contemporary LogistiCs
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Twelfth Edition
Contemporary LogistiCs
Paul R. Murphy, Jr.
A. Michael Knemeyer
New York, NY
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BRIEF CONTENTS Preface xv
PART 1 Overview of Logistics 1 Chapter 1 An Overview of Logistics 2 Chapter 2 Logistics and Information Technology 22 Chapter 3 Strategic and Financial Logistics 41 Chapter 4 Organizational and Managerial Issues in Logistics 54
PART 2 Supply Chain Management 77 Chapter 5 The Supply Chain Management Concept 78 Chapter 6 Procurement 96
PART 3 Elements of Logistics Systems 111 Chapter 7 Demand Management, Order Management,
and Customer Service 112 Chapter 8 Inventory Management 130 Chapter 9 Facility Location 149 Chapter 10 Warehousing Management 168 Chapter 11 Packaging and Materials Handling 185 Chapter 12 Transportation 204 Chapter 13 Transportation Management 224 Chapter 14 International Logistics 243 Glossary 272 Name Index 281 Subject Index 285
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CONTENTS
Preface xv
Part I Overview of Logistics 1
Chapter 1 AN OVERVIEW OF LOGISTICS 2 Economic Impacts of Logistics 2
Logistics: What It Is 3
The Increased Importance of Logistics 5
A Reduction in Economic Regulation 5
Changes in Consumer Behavior 6
Technological Advances 7
Advances in Retailing 8
Globalization of Trade 8
The Systems and Total Cost Approaches to Logistics 8
Logistical Relationships within the Firm 10
Finance 10
Production 11
Marketing 11
Marketing Channels 13
Activities in the Logistical Channel 15
Customer Service 16
Demand Forecasting 16
Facility Location Decisions 16
International Logistics 16
Inventory Management 16
Materials Handling 16
Order Management 16
Packaging 16
Procurement 17
Reverse Logistics 17
Transportation Management 17
Warehousing Management 17
Logistics And Supply Chain Careers 17 Summary 19 • Key Terms 18 • Questions for Discussion and Review 19 • Suggested Readings 19
▶ CASE 1.1 KiddieLand and the Super Gym 20
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viii Contents
Chapter 2 LOGISTICS AND INFORMATION TECHNOLOGY 22 General Types of Information Management Systems 23
Office Automation Systems 24
Communication Systems 25
Transaction Processing Systems (TPS) 26
Management Information Systems (MIS) and Executive Information Systems(EIS) 28
Decision Support Systems (DSS) 29
Enterprise Systems 31
The Internet’s Influence on Logistics 32
Online Retailing 32
Cloud Computing 34
Electronic Procurement 34
Internet of Things 35
Information Technology Challenges 36 Summary 37 • Key Terms 37 • Questions for Discussion and Review 37 • Suggested Readings 37
▶ CASE 2.1 To Invest or not to Invest? that is the question 38
Chapter 3 STRATEGIC AND FINANCIAL LOGISTICS 41 Connecting Strategy to Financial Performance 42
Basic Financial Terminology 44
Income Statement 44
Balance Sheet 45
Statement of Cash Flows 46
Reporting Requirements 46
Strategic Profit Model 47
Logistics Connections to Net Profit Margin 49
Logistics Connections to Asset Turnover 49
Balanced Scorecard 49
Logistics Activity Measures 50
Transportation Measures 50
Warehousing Measures 51
Inventory Measures 51
Design and Implementation of Measures 51 Summary 52 • Key Terms 52 • Questions for Discussion and Review 52 • Suggested Readings 53
▶ CASE 3.1 Brant Freezer Company 53
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Contents ix
Chapter 4 ORGANIZATIONAL AND MANAGERIAL ISSUES IN LOGISTICS 56 Organizing Logistics within the Firm 56
Organizational Structure for Logistics 57
Organizational Design for Logistics 58
Managerial issues in Logistics 59
Productivity 60
Quality 62
Risk 64
Sustainability 69
Complexity 71 Summary 72 • Key Terms 72 • Questions for Discussion and Review 72 • Suggested Readings 73
▶ CASE 4.1 Red Spot Markets Company 73
Part II Supply Chain Management 77
Chapter5THESUPPLYCHAINMANAGEMENTCONCEPT 78 Evolution of Supply Chain Management 78
Supply Chain Management Process Frameworks 80
Enablers of SCM Implementation 81
Understanding the Implications of Increased Customer Power 82
Establishing Appropriate Relationship Structures 83
Leveraging Technology for Enhanced Visibility and Communication 85
Use of Supply Chain Facilitators 86
Barriers to SCM Implementation 88
Regulatory and Political Considerations 88
Lack of Top Management Commitment 88
Reluctance to Share, or Use, Relevant Information 88
Incompatible Information Systems 89
Incompatible Corporate Cultures 89
Globalization Challenges 90
Supply Chain Integration 90 Summary 91 • Key Terms 91 • Questions for Discussion and Review 92 • Suggested Readings 92
▶ CASE 5.1 Johnson Toy Company 93
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Chapter6PROCUREMENT 96 Procurement Objectives 97
Supplier Selection and Evaluation 98
Procurement Portfolio Approach 100
Supplier Development (Reverse Marketing) 101
Global Procurement (Sourcing) 101
Sustainable Procurement 103
Social Responsibility 103
Investment Recovery 104
Supply Chain Finance 105 Summary 105 • Key Terms 105 • Questions for Discussion and Review 106 • Suggested Readings 106
▶ CASE 6.1 Tempo Ltd. 107
Part III Elements of Logistics Systems 111
Chapter 7 DEMAND MANAGEMENT, ORDER MANAGEMENT, AND CUSTOMERSERVICE 112 Demand Management 112
Demand Forecasting Models 113
Demand Forecasting Issues 114
Order Management 114
Order Transmittal 115
Order Processing 115
Order Picking and Assembly 116
Order Delivery 118
Customer Service 119
Time 120
Dependability 120
Communication 120
Convenience 121
Managing Customer Service 121
Establishing Customer Service Objectives 121
Measuring Customer Service 123
Customer Profitability Analysis 124
Service Failure and Recovery 124 Summary 125 • Key Terms 125 • Questions for Discussion and Review 126 • Suggested Readings 126
▶ CASE 7.1 Handy Andy, Inc 127
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Chapter8 INVENTORYMANAGEMENT 130 Inventory Classifications 131
Inventory Costs 131
Inventory Carrying Costs 132
Ordering Costs 133
Trade-Off Between Carrying and Ordering Costs 133
Stockout Costs 134
Trade-Off Between Carrying and Stockout Costs 135
When to Order How Much to Order 136
Economic Order Quantity 137
Conditions of Uncertainty 139
Inventory Flows 139
Inventory Management: Special Concerns 140
ABC Analysis of Inventory 140
Dead Inventory 141
Inventory Turnover 142
Complementary and Substitute Products 142
Contemporary issues with Managing Inventory 143
Lean Manufacturing 143
Service Parts Logistics 145
Vendor-Managed Inventory 146 Summary 146 • Key Terms 146 • Questions for Discussion and Review 147 • Suggested Readings 147
▶ CASE 8.1 Low Nail Company 148
Chapter9FACILITYLOCATION 149 The Strategic Importance of Facility Location 150
Determining The Number of Facilities 151
General Factors Influencing Facility Location 152
Natural Resources 152
Population Characteristics—Market for Goods 154
Population Characteristics—Labor 154
Taxes and Incentives 156
Transportation Considerations 156
Proximity to Industry Clusters 158
Trade Patterns 158
Quality-of-Life Considerations 159
Locating in other Countries 159
Contents xi
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Specialized Location Characteristics 160
Free Trade Zones 160
Finding the Lowest-Cost Location using grid systems 161
Grid Systems 161
Facility Relocation and Facility Closing 163 Summary 164 • Key Terms 164 • Questions for Discussion and Review 164 • Suggested Readings 164
▶ CASE 9.1 All-Indian Logistics Services 166
Chapter10WAREHOUSINGMANAGEMENT 168 The Role of Warehousing in a Logistics System 168
Public, Private, Contract, and Multiclient Warehousing 170
Public Warehousing 170
Private Warehousing 172
Contract Warehousing 173
Multiclient Warehousing 173
Design Considerations in Warehousing 173
General Considerations 173
Trade-offs 174
Fixed versus Variable Slot Locations for Merchandise 174
Build Out (Horizontal) versus Build Up (Vertical) 175
Order-Picking versus Stock-Replenishing Functions 175
Two-Dock versus Single-Dock Layout 175
Conventional, Narrow, or Very Narrow Aisles 175
Degree of Warehouse Automation 176
Other Space Needs 176
Warehousing Operations 177
Warehousing Productivity Analysis 177
Safety Considerations 177
Hazardous Materials 180
Warehousing Security 180
Cleanliness and Sanitation Issues 181 Summary 182 • Key Terms 182 • Questions for Discussion and Review 182 • Suggested Readings 183
▶ CASE 10.1 Minnetonka Warehouse 183
Chapter11PACKAGINGANDMATERIALSHANDLING 185 Product Characteristics 185
Packaging Fundamentals 186
Functional Tradeoffs 187
Package Testing and Monitoring 188
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Labeling 188
Issues in Packaging 190
Environmental Protection 190
Metric System 192
Identifying Packaging Inefficiencies 192
Packaging’s Influence on Transportation Considerations 193
Unit Loads in Materials Handling 195
The Unit Load Platform 196
Beyond the Unit Load 197
Materials Handling 197
Materials Handling Principles 200
Materials Handling Equipment 200 Summary 201 • Key Terms 201 • Questions for Discussion and Review 202 • Suggested Readings 202
▶ CASE 11.1 Let There be Light Lamp Shade Company 203
Chapter12TRANSPORTATION 204 Comaparing and Contrasting Transportation Infrastructure 205
Transportation Modes 206
Airfreight 206
Motor Carriers 207
Pipelines 209
Railroads 210
Water 210
Intermodal Transportation 211
Transportation Specialists 213
Transportation Regulation 215
Environmental Regulation 215
Safety Regulation 216
Economic Regulation 216
Legal Classification of Carriers 217 Summary 219 • Key Terms 219 • Questions for Discussion and Review 219 • Suggested Readings 220
▶ CASE 12.1 HDT Truck Company 220
Chapter 13 TRANSPORTATION MANAGEMENT 224 Rate (Pricing) Considerations 225
Rate Determination 225
Rate and Service Negotiations 228
Modal and Carrier Selection 234
Documentation 235
Contents xiii
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Bill of Lading 235
Freight Bill 237
Freight Claims 237
Making and Receiving Shipments 238
Consolidating Small Shipments 238
Demurrage and Detention 240
Routing 240
Tracking and Expediting 241
Transportation Service Quality 241 Summary 242 • Key Terms 242 • Questions for Discussion and Review 243 • Suggested Readings 243
▶ CASE 13.1 Chippy Potato Chip Company 242
Chapter14 INTERNATIONALLOGISTICS 245 Macroenvironmental Influences on International Logistics 246
Political Factors 246
Economic Factors 248
Cultural Factors 249
International Documentation 251
Terms of Sale 251
Group 1: Terms that apply to any mode of transport 252
ExW (Exworks) 252
FCA (Free Carrier) 252
CPT (Carriage Paid To) 252
CIP (Carriage and Insurance Paid To) 252
DAT (Delivered at Terminal) 252
DAP (Delivered at Place) 253
DDP (Delivered duty Paid) 253
Group 2: Terms that Apply to Sea and Inland Waterway Transport Only 253
FAS (Free Alongside Ship) 253
FOB (Free on Board) 253
CFR (Cost and Freight) 253
CIF (Cost, Insurance, and Freight) 253
Methods of Payment 253
International Trade Specialists 255
International Freight Forwarders 255
Nonvessel-Operating Common Carriers 256
Export Management Companies 256
Export Packers 257
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xv
Transportation and Inventory Considerations in International Logistics 257
Ocean Shipping 258
Shipping Conferences and Alliances 259
International Airfreight 260
Surface Transport Considerations 260
International Trade Inventories 261
Logistics Performance Index 262 Summary 263 • Key Terms 263 • Questions for Discussion and Review 264 • Suggested Readings 264
▶ CASE 14.1 Nurnberg Augsburg Maschinenwerke (N.A.M) 265
Glossary 272 Name Index 281 Subject Index 285
Contents xv
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This edition of Contemporary Logistics reflects a business landscape that is characterized by-geopolitical tensions in various parts of the world, steadily increasing trade among countries and across continents, supply chain vulnerabilities caused by severe natural disasters, and an unabated pace of technological advancement. Although these and other events present both-challenges and opportunities for logis- tics managers, the logistics discipline still remains fun, exciting, and dynamic—characteristics that are reflected in our revision.
WHAT’S NEW IN THIS EDITION?
This edition reflects input from reviewers, adopters, and other interested parties in terms of structure, presentation, and content. Specific modifications include the following:
• This edition welcomes a new coauthor, A. Michael Knemeyer, currently Associate Professor of Logistics at the Fisher College of Business, The Ohio State University. Mike’s impressive blend of practical, academic, and consulting experience in logistics and supply chain management provides this edition with fresh insights and perspectives.
• This edition contains one new end-of-chapter case, Case 9-1 (“All-Indian Logistics Services”), and modifications of several other cases. For example, some case content, as well as several discussion questions, have been changed in Cases 7-1 (“Handy Andy, Inc.”), 11-1 (“Let There Be Light Lamp Shade Company”), and 14-1 (“Nürnberg Augsburg Maschinenwerke (N.A.M.)”).
• Each chapter in this edition has been revised and incorporates new examples and references. For example, Chapter 1’s discussion of the globalization of trade reports the average growth rate of world trade between 1991 and 2011 (as opposed to between 1997 and 2007 in the tenth edition). As another example, Chapter 14’s discussion of Incoterms reflects the revisions associated with Incoterms 2010, which were effective at the beginning of 2011.
• New content has been added throughout this edition. For example, Chapter 1 now includes a discussion of the rapidly emerging topic of humanitarian logistics. In addition, the “Logistics Activity Measures” section in Chapter 3 contains an expanded discussion of warehousing and inven- tory management performance measurements. Chapter 6 has added a subsection, “Procurement Portfolio Approach,” that highlights Kraljic’s Portfolio Matrix.
• Tables and figures containing country and industry data have been either revised or updated. Examples include Table 1-1, “The Cost of the Business Logistics System in Relation to a Country’s Gross Domestic Product”; Figure 10-3, “2012 Liberty Mutual Workplace Safety Index Findings”; and Table 12-1, “Infrastructure Statistics in Several Countries.”
• The list of Key Terms at the beginning of each chapter has been modified in the eleventh edition, and each key term is defined in the Glossary. New Key Terms in this edition include humanitarian logistics, big data, Logistics Uncertainty Pyramid Model, near-sourcing, and total cost of owner- ship, among others.
• The end-of-chapter Suggested Readings in the eleventh edition have been revised and over 60 percent of them have been published since 2009.
PREFACE
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xviii Preface
INSTRUCTOR SUPPLEMENTS
Supplements are available for adopting instructors to download at www.pearsonhighered.com Registration is simple and gives the instructor immediate access to new titles and new editions. Pearson’s dedicated technical support team is ready to help instructors with the media supplements that accompany this text. The instructor should visit support.pearson.com/getsupport for answers to frequently asked questions and for toll-free user support phone numbers. Supplements include the following:
• Instructor’s Manual • PowerPoint Slides
The current edition of Contemporary Logistics has been prepared by Paul Murphy and Mike Knemeyer, and they welcome your comments and suggestions at drmurphy@jcu.edu (Paul) and knemeyer.4@osu.edu (Mike). Paul and Mike gratefully acknowledge the important contributions that the late Donald F. Wood, James C. Johnson, and Daniel L. Wardlow made to earlier editions.
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1
P art 1 of Contemporary Logistics introduces the many dimensions of the complex and dynamic subject of logistics. Chapter 1 presents an overview of logistics and introduces you to what logistics is and why it is important. The chapter covers the economic impact of logistics and discusses how
logistics interacts with other functions, such as marketing, in an organization. Chapter 2 provides an overview of the general types of information management systems that are
applicable across each business function, and it provides examples of how these general types of information systems are specifically applied in logistics management. Chapter 2 also explores the Internet's influence on logistics and looks at some of the challenges associated with information technology.
Chapter 3 discusses the strategic financial outcomes influenced by logistics decisions. It uses the strategic profit model to highlight how logistics activities influence the key corporate financial measures of net income, capital employed, and return on capital employed.
Chapter 4 examines organizational and managerial issues in logistics. The chapter begins by looking at organizational structure and organizational design for logistics. Chapter 4 also discusses select managerial issues in logistics such as productivity, theft and pilferage, and the impact of terrorism on logistics systems.
OVERVIEW OF LOGISTICS PART I
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1
ECONOMIC IMPACTS OF LOGISTICS
Although the logistics discipline today is vastly different from what it was like when the first edition of this book was published in the 1970s, one thing that remains constant is the economic impact of logistics. Before defining what logistics is, we believe it is important to discuss the economic aspects of logistics; you might be surprised at its significant economic impact. From a macroeconomic per- spective, Table 1.1 presents logistics costs in relation to gross domestic product (GDP) for a select group of countries. Although absolute and relative logistics costs in relation to GDP vary from country to country, logistics is most definitely an important component in any country’s economy.
More specifically, logistics can play an important role in a nation’s economic growth and devel- opment. For example, relatively high logistics costs (as a percentage of GDP) in the People’s Republic of China (China) continue to restrict the country’s economic development; in particular, the high costs of highway transportation have severely constrained the growth of China’s e-commerce mar- ket.1 In a similar fashion, the growth of e-commerce sales in India is challenged by logistical ineffi- ciencies to include poor roads and inferior transportation equipment.2
Apart from the previous examples of macrolevel economic impacts, the economic impacts of logistics can affect individual consumers such as you. These impacts can be illustrated through the concept of economic utility, which is the value or usefulness of a product in fulfilling customer needs or wants. The four general types of economic utility are possession, form, time, and place; logistics clearly contributes to time and place utilities.
Possession utility refers to the value or usefulness that comes from a customer being able to take possession of a product. Possession utility can be influenced by the payment terms associ- ated with a product. Credit and debit cards, for example, facilitate possession utility by allowing the customer to purchase products without having to produce cash or a cash equivalent. Likewise,
1 Hua Wang, “High Logistics Cost, Toll Road and Institutional Factors Countermeasure in China,” Journal of Modern Accounting and Auditing, 7, no. 11 (2011): 1301–1306. 2 Sean McLain and Newley Purnell, “Indian Startups Vie to Win E-Commerce Battle,” The Wall Street Journal, October 25, 2015.
An Overview Of LOgistics
Learning Objectives
1.1 To discuss the economic impacts of logistics 1.2 To define what logistics is 1.3 To analyze the increased importance of logistics 1.4 To discuss the systems and total cost approaches to logistics 1.5 To expose you to logistical relationships within the firm 1.6 To introduce you to marketing channels 1.7 To provide a brief overview of activities in the logistics channel 1.8 To familiarize you with logistics careers
Learning Objective 1.1
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Chapter 1 • An Overview of Logistics 3
automotive leases allow customers to take possession of a more desirable model than would be pos- sible with conventional automotive loans.
Form utility refers to a product’s being in a form that (1) can be used by the customer and (2) is of value to the customer. Although form utility has generally been associated with production and manufacturing, logistics can also contribute to form utility. For example, to achieve production economies (i.e., lower cost per unit), a soft-drink company may produce thousands of cases of a certain type of soft drink (e.g., diet cola). You’re not likely to purchase diet cola by the thousands of cases (unless you’re having a really big social event!) but rather in smaller lot sizes, such as a six- or twelve-pack. Through allocation, logistics can break the thousands of cases of diet cola into the smaller quantities that are desired by customers.
Place utility refers to having products available where they are needed by customers; prod- ucts are moved from points of lesser value to points of greater value. Continuing with the diet cola example, place utility is increased by moving the soda from a point of lesser value (e.g., stored in a warehouse) to a point of greater value (e.g., on a supermarket shelf).
Closely related to place utility is time utility, which refers to having products available when they are needed by customers. It is important to recognize that different products have different sensitivities to time; three-day late delivery of perishable items likely has more serious consequences than three-day late delivery of nonperishable items.
Simultaneously achieving possession, form, place, and time utility goes a long way toward facilitating—but not guaranteeing—customer satisfaction. Consider the experience of a former stu- dent who placed an online order of Valentine’s Day flowers for his out-of-state girlfriend. The seller facilitated possession utility by allowing the student to pay by credit card, and a healthy arrangement of the correct bouquet (form utility) arrived at the girlfriend’s residence on Valentine’s Day (place and time utility). Although the seller provided possession, form, place, and timely utility, the buyer was quite unsatisfied with his purchase. The problem: The greeting card that accompanied the flow- ers had the wrong name for the girlfriend (but the right name for the boyfriend)!
LOGISTICS: WHAT IT IS
Now that you have been introduced to select economic impacts of logistics, it’s important to define what logistics is. This book adopts the definition promulgated by the Council of Supply Chain Management Professionals (CSCMP), one of the world’s most prominent organizations for logistics professionals. According to the CSCMP, “Logistics management is that part of supply chain manage- ment that plans, implements, and controls the efficient, effective forward and reverse flow and storage of goods, services, and related information between the point of origin and the point of consump- tion in order to meet customers’ requirements.”3
Learning Objective 1.2
3 www.cscmp.org/about-us/supply-chain-management-definitions
TABLE 1.1 The Cost of the Business Logistics System in Relation to a Country’s Gross Domestic Product
Country Logistics as a Percentage of GDP
United States 8.5
Brazil 12.0 South Africa 12.8 India 13.0 People’s Republic of China 18.0 Vietnam 25.0 Indonesia 27.0
Sources: Various country reports.
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4 Part I • Overview of Logistics
Let’s analyze this definition in closer detail. First, logistics is part of supply chain manage- ment. We’ll talk about supply chains and supply chain management in greater detail in Chapter 5, but the key point for now is that logistics is part of a bigger picture in the sense that supply chain management focuses on coordination among business functions (such as marketing, production, and finance) within and across organizations. The fact that logistics is explicitly recognized as part of supply chain management means that logistics can affect how well (or how poorly) an individual firm—and its associated supply chain(s)—can achieve goals and objectives.
The CSCMP definition also indicates that logistics “plans, implements, and controls.” Of par- ticular importance is the word and, which suggests that logistics should be involved in all three activi- ties—planning, implementing, controlling—and not just one or two. Note that the CSCMP defini- tion also refers to “efficient and effective forward and reverse flows and storage.” Broadly speaking, effectiveness can be thought of as, “How well does a company do what it says it’s going to do?” For example, if a company promises that all orders will be shipped within 24 hours of receipt, what percentage of orders are actually shipped within 24 hours of receipt? In contrast, efficiency can be thought of as how well (or poorly) company resources are used to achieve what a company promises it can do. For instance, some companies use premium or expedited transportation services—which cost more money—to cover for shortcomings in other parts of their logistics systems.
With respect to forward and reverse flows and storage, for many years logistics focused only on forward flows and storage, that is, those directed toward the point of consumption. Increasingly, however, the logistics discipline has recognized the importance of reverse flows and storage (reverse logistics), that is, those that originate at the point of consumption. Although the majority of the discus- sion in this book focuses on forward logistics, many companies today recognize the tactical and strategic implications of reverse logistics. Indeed, reverse logistics continues to grow in importance as individual companies, and select supply chains, recognize it as an opportunity for competitive advantage.4 One illustration of this is FedEx Corporation’s (a leading logistics service provider) 2015 acquisition of GENCO, a logistics service provider with long-standing expertise in reverse logistics.
The CSCMP definition also indicates that logistics involves the flow and storage of “goods, services, and related information.” Indeed, in the contemporary business environment, logistics is as much about the flow and storage of information as it is about the flow and storage of goods. The importance of information in contemporary logistics is captured by Fred Smith, CEO and chairman of FedEx, who believes that “information about the package is as important as the package itself.”5 Furthermore, an important contemporary logistics and supply chain axiom involves the ability to substitute information for inventory;6 for example, the cash register at many contemporary retailers also tracks what and when products are being purchased.
Finally, the CSCMP definition indicates that the purpose of logistics is “to meet customer requirements.” This is important for several reasons, with one being that logistics strategies and activities should be based on customer wants and needs, rather than the wants, needs, and capabili- ties of manufacturers or retailers. Contemporary information technology facilitates an understand- ing of customer wants and needs and this technology allows for real-time interactive communication with customers—a key to meeting customer requirements.