case studies

We have provided several examples of previously conducted assignments for clients. In each case study, we have outlined the challenge, the solution and the end result.

Supply Chain Reorganization

Industries We Serve
  • Adhesives & Sealants
  • Automotive
  • Building Materials
  • Chemicals
  • Construction Products
  • Food & Beverage
  • Inks
  • Material Sciences
  • Paint & Coatings
  • Personal Care
  • Pharmaceuticals
  • Plastics
  • Polymer Sciences
  • Printing Industries
  • Private Equity
 

Problem
A mid-sized specialty chemicals company which supplies the plastics, inks and packaging industries, was in trouble. Its service levels were at an all time corporate low and customer-service fill rates were below 80%. Inventory levels were at an all time high -- in an attempt to improve service levels. Supply chain costs were nearly worst-in-class according to a recently performed Orr & Boss benchmarking study. Customer satisfaction was going from bad to worse.

Solution
Four important improvement objectives were identified and ultimately achieved:

  • New View of the Supply Chain: Move the company away from viewing its supply chain organization as a series of independent functions (silo management) to viewing it as a fully integrated system with the same goal.
  • Process Improvements: Make dramatic improvements in the critically important supply chain processes such as supply and demand planning, sourcing and procurement, order management, transportation and logistics, and customer support.
  • Institute a New S&OP Process: Based upon best-in-class models, redesign and implement a highly effective Sales and Operations Planning (S&OP) process.
  • A New Supply Chain Organization: Create a new, highly integrated global supply chain organization that is capable of supporting lower costs, faster cycle times and higher levels of customer service.

Results

  • Inventory levels were reduced by 20%.
  • Overall cost reductions of nearly 3% of sales dropped to the bottom line.
  • North American operations improved customer service levels by 12%.
  • The number of customer complaints was reduced dramatically.