Industry Results

Jewelry Manufacturing

• Achieved 20% reduction in inventory (while SKUs increased 20%)
• Dramatic improvement in on time shipments
• 15% increase in Sales and 20% increase in SKUs

Jewelry Retail

Engineering Polymers

• Implemented DRP in 8 countries
• Integrated with existing regional forecast, production planning, scheduling, and S&OP systems
• Improved Customer Service (identified inventory shortfalls for specific SKUs)
• Reduced working capital
• 30% Inventory Reduction
• Simplified Planning Process
• Increased quality of decision making
• Increased visibility of inventory, decisions, problems
• Standardized business practices
• Implemented DRP in 8 countries

Industrial Yarn

• 59% Reduction in 1st Grade Inventory
• Forecast Error (MAD) Reduced by 36%

Textile Yarn

• 50% Reduction in Standard Inventory
• %MAD Forecast Error Reduced from 44% to 28% (1 month horizon)

Commercial Carpet

• 15% Inventory reduction
• Service Levels improved to +90% On-time shipment

Residential Carpet

• Inventory Level reduced by +$100M in less than 1 year of use
• Increased profitability
• Fill rates improved from 80% to +90%
• Yarn, greige, carpet, warehousing planned and optimized simultaneously
• Improved Planning manpower efficiency
• +30,000 individual running line SKUs, +150,,000 including inactive SKUs with inventory
• Average of 4 storage locations per SKU
• 5 million historical shipment records processed in each LTT run
• 30,000 Bill-of-materials records
• Start to finish run time less than 2 hours

Industrial Chemicals

• Intermediate inventory reduced by 50%
• Product Wheel cycle reduced by 40%
• Planning "view" extended from 2-3 weeks to 6-9 months
• High quality raw material forecast for suppliers
• Reduced inventories from 130 to 90 days