{"id":2082,"date":"2022-06-15T16:16:35","date_gmt":"2025-10-07T10:31:20","guid":{"rendered":"https:\/\/www.elixirr.com\/en-gb\/?post_type=case_study&#038;p=2082"},"modified":"2025-10-29T15:01:03","modified_gmt":"2025-10-29T15:01:03","slug":"a-major-us-manufacturer-supply-chain-and-planning-optimisation","status":"publish","type":"case_study","link":"https:\/\/www.elixirr.com\/en-gb\/case-studies\/a-major-us-manufacturer-supply-chain-and-planning-optimisation\/","title":{"rendered":"A major US manufacturer: supply chain and planning optimisation"},"content":{"rendered":"<section\n    class=\"wp-block-text-block edwp-block layout--spacing-y bg--none\"\n    >\n    <div class=\"wp-block-text-block__container container fade-in\">\n        <div class=\"wp-block-text-block__content wysiwyg\">\n            <p class=\"meta-right-overview\">In a post-COVID-19 world, businesses\u2019 supply chains need to be reimagined. We helped a major US-based manufacturer fully understand the effects that COVID-19 had on its main suppliers and tackle these issues head on by delivering a focused Management Operating System (MOS) and building sustainable prioritisation and scheduling tools \u2014 namely a Procurement Advanced Warning System (PAWS).<\/p>\n<div class=\"hero-meta\">\n<ul class=\"meta-list\">\n<li>Outcome 1: Created a focused Management Operating System (MOS) to adapt to the new reality at pace, bringing structure to escalations and defining and rolling out a process to quickly deal with issues<\/li>\n<li>Outcome 2: Created a Procurement Advanced Warning System (PAWS) which has been attributed to doubling daily revenue figures by the client<\/li>\n<li>Outcome 3: PAWS prioritizes $40m worth of part shortages, reducing the time it takes a buyer to understand necessary action by over 90%<\/li>\n<\/ul>\n<\/div>\n        <\/div>\n            <\/div>\n<\/section>\n\n\n<section\n    class=\"wp-block-banner edwp-block layout--spacing-y bg--secondary wp-block-banner--content-right\"\n    >\n    <div class=\"container wp-block-banner__container\">\n        <div class=\"edwp-component edwp-fade-in wp-block-banner__content\">\n            <h2 class=\"wp-component-heading wp-component-content__title text--h1\">\n    The challenge<\/h2>                <div class=\"wp-component-content__content wp-component-content__content--cols-1 wysiwyg\">\n                            <div class=\"wp-component-content__column\">\n                    <div class=\"case-study-challenge-block\">\n<p>One of the many implications of the COVID-19 pandemic was the realization that companies must reimagine their supply chains. Failing that, they\u2019ll be left behind, facing serious delays and shortages for manufacturers. From labour shortages to raw material unavailability, and health, safety and environment (HSE) concerns, the pandemic challenged both component suppliers and finished goods manufacturers to face historic and unprecedented obstacles. While many companies stabilised and pivoted operations to manage in a post-COVID economy, it is essential that businesses now understand how COVID-19 has impacted their main suppliers, in order to create a strategy to directly address these issues. We were challenged by a major manufacturer to solve these issues at their most distressed plant.<\/p>\n<p>Our client was facing significant supply chain issues as a result of the pandemic. Our analysis showed that 53% of all production delays were logged due to sourced part shortages, 70% of which were due to raw material shortages, labour shortages, and other supply chain issues \u2013 those caused directly by COVID-19. We also found that an additional 7% of sourced part shortage delays were due to the suppliers\u2019 inability to fulfil orders as accepted due to capacity constraints.<\/p>\n<p>We partnered with our client\u2019s procurement manager and their team of buyers to gain further insight and understand some of the conversations they were having with their suppliers. Comments such as \u201cthe supplier\u2019s supplier is having raw material issues\u201d and \u201cthe McDonalds down the street is offering higher pay than us\u201d bring to light the widespread significance of our client\u2019s challenge.<\/p>\n<p>&nbsp;<\/p>\n<\/div>\n<div class=\"case-study-challenge-block\"><\/div>\n                <\/div>\n                    <\/div>\n                    <\/div>            <\/div>\n<\/section>\n\n\n<section\n    class=\"wp-block-banner edwp-block layout--none bg--secondary wp-block-banner--content-right\"\n    >\n    <div class=\"container wp-block-banner__container\">\n        <div class=\"edwp-component edwp-fade-in wp-block-banner__content\">\n            <h2 class=\"wp-component-heading wp-component-content__title text--h1\">\n    The approach<\/h2>                <div class=\"wp-component-content__content wp-component-content__content--cols-1 wysiwyg\">\n                            <div class=\"wp-component-content__column\">\n                    <div class=\"case-study-challenge-block\">\n<p>Firstly, we conducted an in-depth root cause analysis of the problems our client faced in the\u00a0<a href=\"https:\/\/elixirr.com\/services\/procurement\/procurement-process\/\">procurement process<\/a>. This involved high-level system mapping to understand why SAP (their enterprise resource planning system) wasn\u2019t doing what the team wanted or needed it to do. Our team also partnered with our client\u2019s procurement manager and her team of buyers to analyse over 2,400 orders, which were unable to be released clear to build due to a missing part from a supplier. By engaging with key stakeholders, we took an approach that put their pain points at the heart of the solution.<\/p>\n<p>We created a machine shop schedule to unify production schedules across the plants, ensuring the right parts are made, as well as devising executive dashboards to track issues and resolutions, and installing a playbook to document processes and strategies for long-term benefits. All of these solutions helped streamline the process based on insights from our client and their suppliers.<\/p>\n<p>&nbsp;<\/p>\n<\/div>\n<div class=\"case-study-challenge-block\"><\/div>\n                <\/div>\n                    <\/div>\n                    <\/div>            <\/div>\n<\/section>\n\n\n<section\n    class=\"wp-block-banner edwp-block layout--spacing-y bg--secondary wp-block-banner--content-right\"\n    >\n    <div class=\"container wp-block-banner__container\">\n        <div class=\"edwp-component edwp-fade-in wp-block-banner__content\">\n            <h2 class=\"wp-component-heading wp-component-content__title text--h1\">\n    The value delivered<\/h2>                <div class=\"wp-component-content__content wp-component-content__content--cols-1 wysiwyg\">\n                            <div class=\"wp-component-content__column\">\n                    <p>Our analysis of the current situation led to the creation of a focused Management Operating System (MOS). This has helped our client to adapt to the new reality at pace, bringing structure to escalations and defining a process to quickly deal with issues in an organised manner. We also created tools that identified orders that could be released to the production floor, developing algorithms at pace to unify sources of data. While this normally took our client\u2019s internal teams months to do, we delivered this in just 6 weeks, rapidly accelerating efficiency levels.<\/p>\n<p>In a time when dependency on the global supply chain has been put to the test, we recognise that the most successful businesses are finding creative ways to ensure their future success. So, we created a Procurement Advanced Warning System (PAWS) for our client to help tackle their challenges.<\/p>\n<p>PAWS is an online tool designed to help buyers identify and prioritise the parts they need to purchase, giving them a rolling view of which purchase orders need to be expedited to prevent shortages. Unlike executive dashboards, we designed this tool to be actionable and granular enough for operational buyers at the plant-level. It offers buyers three unique ways to track their most important parts through a prioritised target list, a part deep-dive and a supplier tracking page.<\/p>\n<p>Since creation, PAWS has doubled daily revenue figures. It has prioritised $40m worth of part shortages for our client and reduced the time it takes a buyer to understand necessary action by 90%.<\/p>\n                <\/div>\n                    <\/div>\n                    <\/div>            <\/div>\n<\/section>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":1,"featured_media":55345,"template":"","related_service":[51],"related_industry":[56],"class_list":["post-2082","case_study","type-case_study","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v27.1 (Yoast SEO v27.1.1) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>A major US manufacturer: supply chain and planning optimisation - Elixirr<\/title>\n<meta name=\"description\" content=\"A major U.S. manufacturer re-imagined its post-COVID supply chain\u2014built a Management Operating System (MOS), deployed a PAWS tool prioritising $40 m in part 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fill=\"none\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\">\n<g>\n<path d=\"M23.4141 0.539062C36.1232 0.539183 46.4258 10.8416 46.4258 23.5508C46.4257 36.2599 36.1231 46.5624 23.4141 46.5625C10.7049 46.5625 0.402465 36.2599 0.402344 23.5508C0.402344 10.8415 10.7048 0.539062 23.4141 0.539062ZM23.4141 1.68945C11.3606 1.68945 1.55273 11.4974 1.55273 23.5508C1.55286 35.6041 11.3607 45.4111 23.4141 45.4111C35.4673 45.411 45.2743 35.604 45.2744 23.5508C45.2744 11.4974 35.4674 1.68957 23.4141 1.68945Z\" fill=\"currentColor\"\/>\n<path d=\"M19.2841 33.6992C18.9579 33.6986 18.6374 33.6111 18.3543 33.4454C17.7167 33.0759 17.3203 32.3585 17.3203 31.5797V15.8189C17.3203 15.0379 17.7167 14.3227 18.3543 13.9531C18.6442 13.7827 18.9735 13.6951 19.3078 13.6994C19.6421 13.7037 19.9692 13.7998 20.2548 13.9776L33.4237 22.0406C33.6981 22.2166 33.9244 22.461 34.0812 22.751C34.238 23.0409 34.3203 23.3668 34.3203 23.6982C34.3203 24.0295 34.238 24.3555 34.0812 24.6454C33.9244 24.9353 33.6981 25.1798 33.4237 25.3558L20.2527 33.421C19.9604 33.6017 19.6256 33.6979 19.2841 33.6992Z\" fill=\"currentColor\"\/>\n<\/g>\n<\/svg>\n<\/span>            <\/div>\n                        <\/figure>\n        <div class=\"wp-component-card__content edwp-row-load\">\n                                    <p class=\"wp-component-card__eyebrow\">\n                Procurement            <\/p>\n                <a href='https:\/\/www.elixirr.com\/en-gb\/case-studies\/a-major-us-manufacturer-supply-chain-and-planning-optimisation\/' class='wp-component-card__title'>\n            <h2>\n                A major US manufacturer: supply chain and planning optimisation\n            <\/h2>\n        <\/a>                                                            <div class=\"wp-component-card__meta\">\n                                            <p class=\"wp-component-card__date\">\n                            15 June 2022                        <\/p>\n                                                                <div class=\"wp-component-card__terms\">\n                                                                                                                                                                                                                <div class=\"wp-component-tags edwp-component\">\n                        <div class=\"wp-component-tags__tag\">\n                Manufacturing            <\/div>\n                                <div class=\"wp-component-tags__tag\">\n                Procurement            <\/div>\n                <\/div>\n                        <\/div>\n                                    <\/div>\n                                                    <div class=\"wp-component-card__button-wrapper\">\n                    <button class=\"btn btn--link arrow wp-component-card__button\">\n                                                                            Read more                                                                            <span 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