Sales & Operations Planning

Manufacturing
 

Context

A client in the textile manufacturing industry was struggling to effectively plan production and deliver customer orders OTIF:

  • Production was continuously interrupted by unscheduled ‘urgent’ orders and sample requirements

  • Inaccurate sales forecasts impacted raw materials availability

  • Frequent change-overs and retooling impacted OEE and resulted in a build up of in-process inventory

Design

&

Installation

 

Our key activities included:​​

  • Joint approach to design integrated S&OP processes

  • Introduction of sales forecasts

  • Weekly production plans fixed with the incorporation of sampling orders

  • Implementation of raw material inventory system (Net stock)

  • Effective KPI reporting

Outcomes

 

The S&OP system implementation significantly reduced WIP inventory, while production volumes and revenue both increased year-on-year.

  • Plan attainment averaged over 98% in busiest time of year

  • Plant efficiencies increased by 12% year-on-year

  • Raw material inventory was reduced by c. 25% within 4 months