Case Study Archives

Semiconductor Manufacturer Achieves 100% Delivery Performance – Planning Case Study

Production Planning Case Study Summary A global semiconductor manufacturer with fabrication facilities across three continents faced the complex challenge of managing semiconductor production lines characterized by long lead times, interplant dependencies, frequent equipment breakdowns, and highly fluctuating demand patterns. The company struggled with traditional planning methods that relied on historical fixed lead-times and pre-defined bottlenecks, …

Paulaner Brewery Weather Forecast Accuracy – Demand Planning Case Study

Summary – Production planning case study Paulaner, one of Germany’s largest and most recognized breweries headquartered in Munich, produces 3 brands across 20 types of beer with up to 30 packaging variations for both domestic (70%) and international (30%) markets. The brewery faced unique operational challenges due to its central Munich location, which severely limited …

SK Hynix Reduced WIP in Semiconductor Boosted Memory Production – Scheduling Case Study

Semiconductor memory manufacturing summary SK Hynix, a $22.5 billion Korean semiconductor manufacturer with production facilities across Korea, USA, and China, specializes in memory products including DRAM, SRAM, and FLASH memory. The company faced critical challenges in maintaining competitive positioning, including the need to reduce manufacturing cycle times, accelerate time-to-market for premium products, and optimize resource …

Gulistan Carpet Cuts Lead Times 43% with APS – Case Study

Case Study Summary Gulistan Carpet, a leading carpet manufacturer based in North Carolina, has been producing high-quality residential and commercial carpets for nearly a century. The company faced significant challenges managing complex production operations across 2,000 different colors and 70 styles while serving 4,000 retailers nationwide, resulting in lengthy three-week lead times and high inventory …

Medical Device Co. Cuts Cycle Time 40% w/ AI Planning – Case Study

Global Medical Device Manufacturing Needs The company is a leading global maker of medical devices with almost 30 manufacturing sites worldwide. The objectives of the project were to implement a planning and scheduling solution with the following objectives: Project Objectives Strategic initiative aligned to the manufacturing operations digital roadmap. Address planning & scheduling gap in …

Japanese Textile Giant Cuts Production Lead Time 70% w/ Planning – Case Study

Dramatic Reduction of Greige and Dye Processes by as Much as Two-Thirds Twice a year – in January and July – big sale events in the apparel world promise a field day for bargain-hunting consumers. But the sales extravaganzas represent huge losses for clothing manufacturers forced to liquidate excess product inventory. One innovative Japanese textile …

Classic Brands Sleep Products Cuts Lost Sales with Demand Planning – Case Study

Challenges in the Sleep Products Manufacturing Industry The business is highly competitive and fast moving, so accurate forecasts with tightly managed inventory is critical for meeting sales and margin targets. The company needs to deal with supply uncertainty for overseas long lead time manufacturing sources and identify revenue at risk. The port delays cause the …

Allergan Pharmaceutical Boosts On-Time Delivery with Planning – Case Study

Planning Challenges in Pharmaceutical Manufacturing Allergan is a multi-national pharmaceutical company present in over 150 countries worldwide that develops and manufactures brand name drugs and medical devices in a number of areas including nervous systems, medical aesthetics and gastroenterology. Allergan had not invested significantly in supply chain and factory planning systems over the years resulting …

Firmenich Reduces Planning Lead Times by 95% in Flavor & Fragrance Manufacturing – Case Study

Customer Challenges: Planning lead times of 15-20 days due to fragmented local systems Lack of global visibility across 24 manufacturing sites Managing complex supply chain with 45,000 products and 10,000 customers Inventory inefficiencies and excess safety stock Manual processes causing delays and errors in order fulfillment Complex formulae with bills of material reaching 20 levels …

Hindustan Consumer Goods Increase Profits with Planning – Case Study

Consumer Goods Manufacturing Challenges in Production Planning: Managing complex supply chain across 2 million square miles with 2,000 suppliers and 7,500 distributors Serving diverse markets (urban vs rural, educated vs uneducated, affluent vs poverty-line consumers) Transportation challenges with dirt roads and seasonal disruptions Need for flexible planning across multiple product lines Promotional campaigns creating manufacturing …

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