Food-Grade and Industrial Phosphorus Processor — Two Plants (Wet and Dry Processes), US and Canada
Client Challenge
A global phosphorus manufacturer was running disconnected facilities with fragmented production systems and no real-time reporting
A global industrial-/food-grade phosphorus processor was mandated by Corporate to modernize and digitalize core processes and systems for two manufacturing plants in the US and Canada
The company struggled with reactive "shooting-from-the-hip" production planning and execution methods
Their manual, complex, and inaccurate production reporting took days to compile, and month-end financial closing took over three weeks due to disconnected manufacturing and financial systems
Client Solution
Process Analysis: Conducted Gemba Walks at both factories to perform Complexity Lean Value Stream Mapping and assessed current state of processes
Master Data Development: Created PDM Master Data Taxonomy for manufactured components, designed inventory lot control systems, and developed structures for regulatory compliance
Future-state Core Process Standardization: Standardized processes across plants using JD Edwards and Lean frameworks
JDE ERP Implementation: Configured JDE modules for planning, inventory, manufacturing, and costing, and designed legacy data conversions
Custom Solution Development: Architected "Hyper Backflush" concept, automated multi-stage Work Order processes, and integrated production with laboratory testing results
Created centralized dashboards and automated reporting Enabled finance, operations, and QA collaboration
Client Impact Results
Financial Close: Month-end closing from more than three weeks to less than one day
Reporting Efficiency: Production reporting from 3–5 days to real-time, automated information
Planning Transformation: Reactive production planning replaced with a proactive SIOP process
Process Integration: Production and inventory reporting fully automated through integration with financial accounting and laboratory test results
Regulatory Compliance: Automated lot tracking — grades, dates, shelf life — for cGMP and CFR Title 21
Client Technologies
JD Edwards ERP (Forecasting, Capacity Planning, Material Planning, PDM, Inventory Management with Lot Control, Manufacturing, Product Costing, Manufacturing Accounting)
“Hyper Backflush” work order automation for bulk rail-car processing driven by lab results
Complexity Lean Value Stream Mapping · BPR · cGMP/CFR Title 21 compliance
