Methodology
Vertical Integration
Concept:
Vertical integration approach is taken by companies to integrate one or two production processes or steps into their own business, instead of relying on external suppliers for those particular requirements. A business can achieve this by acquiring or taking direct control for some of their own suppliers, distributors, or retail locations rather than outsourcing them as external service providers, also it can be done by merging two or more companies which are serving different function in same supply chain.
Types:
Mainly there are two types of vertical integration, one is Forward Integration, when a company takes ownership of downstream process or further along the supply chain like sales or distribution of finished goods. And another is Backward integration, it is when a company acquires an upstream process which is prior to it along the supply chain, for example a fast-food restaurant takes control to some of the agricultural production that supplies ingredients for cooking foods.
Purpose / Advantages
1. To have greater control on supply chain thus fewer disruptions and lower lead time
2. Company can identify possible disruptions in advance also can have more visibility
3. To lower the manufacturing costs by optimizing operations in all verticals based on need
4. Direct control on processes ensured better quality control in each stage as per requirement
5. Lower transportation costs, less turnaround times if the entire process is managed in-house.
Example
In my earlier organization of paper and paperboards manufacturing, brown Kraft paper core pipe was one of the major raw materials, there were few suppliers for core pipes, one local & two from other states. We were facing issues like size variation, moisture content and also on higher lead time for core pipes. Hence it was decided to develop the local supplier with training and guidance in terms of variation reduction, later company acquired that core pipe cutting facility, also upgraded the machines, and deputed 2 resources. Which has lead to eliminate size variation issue also stock out scenarios. This was one backward integration. It was also planned to relocate that facility inside the main plant to reduce the fixed cost further also making logistics and transportation simpler & more cost effective.
Impact on Business Excellence strategy
A successful vertical integration means company the one acquiring, must manage multiple challenges, some of them for which company resources may not be expert as it was not in original core competencies. Also, it increases business complexity as some new processes gets added in existing operations. To deal with these challenges, business excellence strategy must be aligned to get the full potential benefit and the new process must be thoroughly investigated to integrate those operations with existing processes and ongoing systems, it will also help to get upstream or downstream profits.
On the other hand, the business, one getting acquired, may raise good capital if the assets were not getting utilized fully or not making profitable business. Also, the business will get more exposure with the modern tools and techniques used in parent organization, and expertise to make the processes more effective like improving quality considering actual customer requirement.