A Leading Global FMCG Company- Supply Chain Transformation
Case Study
Author: Mark Masterson | 5 minute read
When product complexity increases, traditional forecast-driven models and fragmented storage quickly break down.
TPGs structured approach to loss analysis and Value Stream Mapping, enabled the organization to regain control, reduce cost, and scale with confidence.
The Opportunity
A global manufacturer was facing increasing operational complexity driven by growth and product innovation:
- Severe space constraints across the site
- Materials stored across multiple, fragmented locations
- Highly manual material movement and handling processes
- Forecast-driven supply model creating instability
- Rapid expansion of new product variants
- Branding complexity on non-customer-facing components
- High levels of material obsolescence and write-offs
The Approach
A cross-functional transformation team was initiated using Value Stream Mapping (VSM) to diagnose and redesign the current end-to-end material flow, including:
- Current storage footprint and layout
- Inventory levels and coverage
- Staffing and handling effort, including automation and digital options
- End-to-end material flow (supplier → line)
- Impact of product complexity and forecast variability
Measurable Results, End to End
- Optimized material storage concept reducing fragmentation and motion losses
- Transition from forecast-driven to demand-driven supply
- Simplified material flow from supplier to production line
- Improved product design and supply chain capability alignment
50% Productivity Increase
40% Reduction in Material Losses
36% Reduction in End-to-End Inventory
Meet The Team
Mark Masterson
