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Case Study & Insights From Our Work

Improving On time delivery performance

CLIENT BACKGROUND

A prominent player in the dope-dyed polyester segment, the client managed a highly customized product mix with a vast order book of shades. The dynamic nature of customer demands and planning constraints created challenges in meeting delivery commitments. Recognizing the need for more agile and efficient operations, the client set out to enhance planning precision and service reliability.

KEY CHALLENGES & iNSIGHTS

The client managed a complex product mix with frequent schedule changes and planning constraints, impacting delivery performance. The dynamic environment highlighted the need for a more agile, structured planning approach. This opened the door for improving efficiency and aligning production with customer priorities.

  • Improving delivery compliance
  • Enhancing effective utilization
  • Streamlining inventory norms
  • Reducing order to delivery lead time
HOW WE HELPED

We introduced a collaborative planning model focused on proactive scheduling aligned with customer priorities. A 15-day frozen schedule cycle was implemented to bring stability, supported by optimization metrics to track plan efficiency. We also refined capacity and inventory planning using a hybrid Make-to-Order and Make-to-Forecast approach, improving overall delivery performance and planning efficiency.

  • Developed a collaborative model to schedule capacity proactively than reactively.
  • Using customer priorities, rolled out 15-day Frozen Schedule cycles.
  • Develop Schedule Optimization Metrics to measure the efficiency of the plan.
  • Capacity planning based on hybrid Make-to-Forecast and Make-to-Order model.
  • Masterbatch Inventory planning based on Safety stock, Min-Max levels and inventory thresholds.
Success in business comes from innovation, adaptability, and a relentless focus on efficiency. Transform challenges into opportunities, and growth will follow
John Doe
Designer
OUR IMPACT
0 %
On-time Delivery Improvement

Enhanced efficiency and reduced downtime, leading to better resource utilization and output.

40 %
Planning Efficiency Improved

Optimized processes and technology integration to streamline production and reduce waste.

30 %
Masterbatch Inventory Reduction

Improved quality control measures to minimize production defects and enhance product consistency.

15 %
Masterbatch Ontime delivery improvement

Advanced planning and raw material management to ensure color precision and minimize rework.

  • The Aubuchon team has been delighted with its results. Shannan O’Brien, Aubuchon’s Director of Marketing, noted that they are not only seeing an increase in leads, but also that new leads are a higher quality with a larger average home sale price.
  • You can tell by the leads that are coming in, the quality of the leads has improved. To have this many leads coming through and people saying ‘hey, reach out to us, we want to talk to you,’ it means a lot to us, Shannan said.
GET IN TOUCH
1. BCF Manufacturing Line Utilization

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0 %
2. FDY Utilization Improvement

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0 %
3. Downgrade Reduction

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0 %
4. LDR & Shade failures reduced

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0 %

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