Optimized plant capacity loading for packaging manufacturer, increasing OTIF

PROBLEM

A packaging manufacturer did not have a formal planning system and relied on plant schedulers to collaborate and balance demand and capacity across a network of 3 plants in the US. One of the plants had a very poor OTIF of less than 60% and complained that it was overloaded with demand.

SOLUTION APPROACH

We created an “IBP-Light” project to map out demand and estimate supply. We created a process to get sales to commit to forecasted demand, and created tools to then turn that demand into supply plans based on plant capacity and capability.

The tool was rolled out in collaboration with a joint IBP monthly process, with the sponsorship of the CEO and VP of Operations.

RESULTS

On-Time-In-Full (OTIF) for the problematic plan was increased from less than 60% to over 95%.

The company got a data-based approach to planning in the short term and long term, which also helped inform capital decisions.

FAQs

Frequently Asked Questions

1. What services do you offer?

We provide supply chain optimization, operational improvement, post-merger integration, value creation, and data-driven advisory services for private equity and mid-sized businesses.

2. Who are your typical clients?

Our clients include private equity firms, portfolio companies, and small-to-medium sized businesses seeking operational efficiency and measurable growth.

3. How quickly can you deliver results?

Depending on the engagement, we provide actionable insights and measurable outcomes in weeks, not months, ensuring rapid value creation.

4. Do you provide post-acquisition support?

Yes, we help with integration, SKU transfers, operational alignment, and strategic execution to meet deal thesis objectives.

5. How do you approach decision-making?

We use data-driven methods, rigorous analytics, and evidence-based frameworks to replace assumptions with actionable, value-maximizing decisions.