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Outperform reduced OOS (Out-of-Stock) from 4% to 2.4%, avoiding 2M Cases of lost sales

Coca-Cola

Background

During the integration planning phase of CCBA it was agreed that CCBSA will implement a Demand Driven MRP Supply Chain Planning methodology, focusing on shorter cycle times and more frequent changeovers, synchronising all daily supply chain activities from production, to warehouse, to distribution, according to a calculated model stock as setup in Outperform.

The challenges

  • Data Integration
    The required input data needs to be imported from all six systems, three times a day to support a 24 hour planning cycle that requires morning and afternoon revision of the supply plans and production schedules.
  • System Responsiveness
    The activity increased from a network of five sites to thirteen sites spread across South Africa impacting system responsiveness which required the hardware and network responsiveness to be evaluated.
  • System knowledge/super user availability
    Due to the multiple business system integration projects, the individuals with the system knowledge, acting as super users, were not readily available to the team, causing delays.

The solutions

  • Single SAP platform
    Moving the different businesses onto a single SAP platform, prioritising the businesses that requires manual downloads.
  • Product mapping tables
    Product mapping tables were created to make a single master data list.
  • Training
    Training material was developed to enrol new plants
  • Senior planners
    Central team structure provides for dedicated resources to improve the Demand Driven MRP planning parameters in Outperform.

The impact

Comparing Peak (Oct – Jan) 2015 to 2016, OOS (Out-of-Stock) reduced from 4% to 2.4%, avoiding 2M Cases of lost sales while finish goods inventory remained the same in nominal value.