Alternate Terms: Spares / Raw Materials Inventory Planning
Spares Inventory Management
Large Integrated Telecommunications Provider
Optimized spare parts inventory for central office and field locations. Determined inventory levels required to support both maintenance and new service demand. Found that company could reduce spare parts inventory in excess of $75M (50+%) without reducing customer service performance.
Large Chemicals Manufacturer
Evaluated company’s purchasing, receiving, delivery, spare parts inventory management, stock issuing, repair and obsolete stock disposition processes. Determined that spare parts inventory levels could be reduced by 10% while simultaneously improving service. Identified process improvements resulting in $2.8M+ in annual savings.
Raw Materials Inventory Management
Leading National Health Care Provider
Transformed supply chain supporting organization’s Northern CA network of 16 regional hospitals. Implemented strategic sourcing initiative, which included shifting the bulk of medical supply purchases from 1000+ suppliers to a single distributor, and bypassing the provider’s regional distribution center. Changes resulted in a $7M (22%) decrease in annual distribution expenses, $11M (45%) reduction in inventory, and improved service. Led implementation of inventory management improvements at a pilot facility, resulting in a 69% inventory reduction.
Custom Sheet Metal Fabricator of Precision Parts for Aerospace, Defense and Medical Equipment Industries
Identified and kicked-off implementation of a series of initiatives that will reduce past due order backlog by over $600K (90% reduction). Initiated improvements in the areas of customer and order management, manufacturing and inventory strategy, use of production scheduling and MRP tools, and strategic sourcing. Determined that raw materials could be reduced by 61% and finished goods by 91% without negatively impacting service.
Rapidly Growing Organic Meat and Poultry Producer
Led SKU rationalization effort that reduced number of SKUs by 67% and increased company profitability. Determined that historic method for determining animal requirements was not providing accurate projections of animal needs. Developed spreadsheet-based supply-demand planning capability accurately linking supply with demand for the first time in company history. Developed time series forecasts in MS Excel that improved forecast accuracy. Then converted forecast to subprimal equivalents, and used to determine animal requirements and production schedule by week over the planning horizon. Determined that company supply-demand mix was extremely out of balance. Identified numerous instances where company would be either material or capacity constrained, and would need to secure alternate sources of supply or increase production capacity. Recommended that company look for ways to better promote whole animal utilization.
Helped client evaluate various ERP tools (Oracle NetSuite, JustFood) and select provider to implement chosen package. Defined detailed future state S&OP requirements, and evaluated various package capabilities (Blue Ridge, Kinaxis, Adexa, DemandCaster, JustFood) to meet these needs.
Medical Devices Division of a Fortune 150 Health Care Products Manufacturer
Assessed current state demand / supply planning solution. Determined that acquisition of a new tool would greatly enhance planning capabilities. Identified key business requirements new tool should support, along with short list of planning software providers meeting these needs. Developed business case documenting tool benefits and costs. Established that new tool will generate $6.8M in benefits annually, with IRR exceeding 27%.
Leading US Producer and Marketer of Frozen and Shelf Stable Fruit Products
Served as Solution Architect during the Design Phase on an SAP Integrated Business Planning (IBP) implementation.
Leading Provider of Fitness and Weight Loss Solutions
Performed assessment of company’s largest supplement product to determine ability of supply chain to support a quadrupling in sales over the next 24 months. Areas evaluated included product formulation, quality assurance, sourcing, demand planning, sales and operations planning (S&OP), inventory management, supply planning, purchasing, contract manufacturing, inbound / outbound transportation and warehouse management. Identified, prioritized and initiated implementation of a portfolio of 25+ projects that will enable organization to meet 98% on-time delivery target, reduce costs by over $500K annually, and expand as planned.