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Agricultural Liquid Chemical Manufacturer
An agricultural chemical manufacturer was experiencing increasing supply chain and production costs related to railcar demurrage, partial truckload returns, production line downtime, and material shortages. Customer complaints were growing exponentially due to a rapid increase in new finished product variations and newly introduced packaging options, resulting in shortages and delays. The company needed to identify and address the root causes of these issues while implementing sustainable solutions to improve operational efficiency and customer satisfaction.
I led a comprehensive business transformation: 1) Root Cause Analysis: Deployed Business Transformation Playbook, conducted Gemba Walks across all core processes, and identified JD Edwards ERP limitations as the root cause of planning issues. 2) Production Planning Optimization: Analyzed historical data, implemented level loading techniques, and configured Rate Based Production methodology. 3) Supply Chain Enhancement: Implemented Blanket Purchase Orders, Supplier Scheduling, MRP for Finished Goods, and Purchase Order Receipt Routing. 4) Financial Integration: Implemented Manufacturing Accounting to automate production-related accounting entries. 5) Change Management: Trained personnel, converted open Work Orders to new schedules, and phased out obsolete processes.
Cost Reduction: Reduced railcar demurrage and tanker truck partial load returns by over 95%. Order Fulfillment: Achieved real-time Available-to-Promise commitments during order taking. Supply Chain Visibility: Established visibility of trans-Atlantic port-of-entry ownership and tracking. Financial Efficiency: Reduced month-end financial close from more than two weeks to less than two hours. Process Automation: Successfully implemented Lean O2C, P2P, Rate-based Scheduling, and Automated Supplier Scheduling. Customer Satisfaction: Significantly reduced product shortages and delivery delays.
JD Edwards ERP (Work Order Management, Rate Based Production, MRP), Heijunka (production leveling) techniques, Blanket Purchase Orders and Supplier Scheduling, Purchase Order Receipt Routing, Manufacturing Accounting automation, Forecasting and Material Requirements Planning, Business Transformation Playbook, Gemba Walk assessment techniques, Available-to-Promise (ATP) methodology, Lean Order-to-Cash (O2C) and Procure-to-Pay (P2P) processes
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