Supply Chain Management

Mitigated recall risk for a midsize CPG company by enabling end-to-end quality management.

Recorded an immediate benefit of 11% on the bottom line.

Supply Chain Management

SITUATION

The company was facing significant losses due to the recall of fig bar lots. The Supply Chain group could not figure out where the issue was. We were called in to investigate and problem-solve.

CONTRIBUTING FACTORS

The raw material inspection process was manual and had no cameras covering the manufacturing line. Air pressure, temperature, etc. were not monitored at regular intervals. This created an opportunity for improving the raw material inspection using modern AI tools.

CHALLENGES

Despite modern manufacturing processes, the supply chain was challenged by end-to-end quality control issues, no real-time analysis, and no access to supplier data.

SOLUTION

  • We streamlined the supply chain and enhanced company profitability and the overall user experience.
  • The transformation first focused on enabling real-time end-to-end visibility, revealing supplier risks and manufacturing demand to produce high-quality athlete bars.
  • By deploying an end-to-end quality management system, the quality of bars improved significantly, while mitigating the risks associated with raw material variance.

 

ADDITIONAL BENEFITS

  • A new framework was developed to maximize existing technology and automate repetitive and mechanical tasks.
  • The creation of a Balanced Scorecard for measuring and tracking KPIs for managers increased efficiency and improved productivity.
  • User experience scoring confirmed management satisfaction.
  • An immediate benefit of 11% to the bottom line was recorded.