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Feed, Seed and Fertilizer Production Company
A large feed, seed, and fertilizer cooperative had embarked on a massive, multi-year transformation strategy to improve all corporate, administrative, production, warehousing, distribution, and retail store operations. The company operated seven feed mills and five fertilizer mills with largely manual, inefficient planning processes. Their operations suffered from data integrity issues, rework, customer delivery mistakes, and excessive lead times due to disconnected systems. The 100-year-old organization faced significant cultural resistance to change and needed comprehensive modernization of its processes and systems.
I led a series of strategic initiatives across multiple projects: 1) JD Edwards Education & Implementation: Established educational curriculum, orchestrated training, designed complex data taxonomies for inventory and manufacturing. 2) Two-Level Supply Chain Planning Framework: Architected forecasting and supply chain planning system with centralized corporate planning and decentralized mill execution. 3) Systems Integration: Designed bi-directional interface between JDE and Rockwell Manufacturing systems and created finite scheduling for deliveries. 4) Seed Operations Modernization: Implemented JDE modules for seed processing and warehouse automation. 5) Commodity Price Management: Developed interface for daily commodity price updates into product costing.
Planning Efficiency: Reduced mill daily planning from over 3 hours to less than 30 minutes. Automation: Transformed operations from nearly 100% manual to 90% automated processes. Supply Chain Optimization: Negotiated favorable pricing through centralized purchasing. Scheduling Accuracy: Achieved ~98% on-the-hour accuracy for customer bulk pickup. Inventory Management: Improved retail inventory accuracy from less than 50% to approximately 100%. Cost Reduction: Eliminated multimillion-dollar pallet reuse infrastructure. Price Management: Implemented daily repricing based on commodity fluctuations. Cultural Transformation: Successfully led change in 100-year-old establishment with embedded resistance.
JD Edwards ERP (PDM, Inventory Management, Forecasting, Manufacturing, MRP, Supplier Scheduling, Procurement, Product Costing modules), Rockwell Manufacturing Process Control Systems integration, DSI Barcode and Scanning technology, Advanced Warehousing automation, Two-Level Forecasting and Supply Chain Planning, Blanket Purchase Order (BPO) methodology, Gemba Walk assessment techniques, Lean process re-engineering, Commodity price hedging systems
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