Case Study: Digital Transformation of a Traditional Supply Chain: Challenges and Victories

Client Overview

A leading global manufacturer needed to modernize its aged, traditional supply chain. Dating back to the 1960s, this organization has long relied on legacy systems that can’t keep up with current demands. As the marketplace heats up with pressure and competition, the company has realized its desperate need to digitally transform in order to improve its supply chain efficiency and overall competitiveness.

The Challenge

The following are some of the basic problems that share the common root cause in its traditional supply chain model and which the organization faced:

  1. Inefficient Processes: The time taken in processing the order was also increased considerably since some of its activities were still manual and not customercentered, which averaged to 12 days as against the industry standard of 3 days.
  1. Missed RealTime Data: Realtime tracking capabilities were lacking, resulting in a low level of visibility, with most of the flaws in the inventory management process being caused, though not deliberately. The company faced a 20% increase in excess inventory and a 15% increase in stockouts.
  1. High Operational Costs: Traditional practices of supply chain made operational costs high—logistic costs took up 25% of total supply chain expenditure, as against the industry average cost of 15%.
  1. Poor Scalability: The existing systems were not wellequipped to handle the fluctuations of demand and changes in the forms and varieties of products available in the seasons.

Solution Implemented:

The implementation of a full proof digital transformation strategy was having two primary focuses to move away from such constraints:

  1. Integrated Supply Chain Management (SCM) System:

    Objective: Replace the fragmented legacy systems by building a single SCM platform.

Result: The SCM solution was successful in reducing the order processing time from 12 days to 2 days—an improvement of 83%. Integrated with the realtime data analytics system, it came up with an improved result that was exponential and effective in decisionmaking and operational efficiency.

  1. RealTime Data Analytics and IoT Integration:

    Objective: Having better visibility and inventory management with technological advancement.

Result: IoT sensors with realtime analytics have been able to cut down excess inventory by 30% and reduce stockouts by 25%. The same is achieved through increased forecast accuracy and automatic replenishment of inventory.

  1. Automatically Managed Logistics and Supply Chain Operations:

    Goal: Automate logistics and supply chain operations to achieve cost savings.

 Outcome: Automation reduced logistics expenses by 20%; costs are at parity with the industry average of 15%. 40% of operational downtimes were averted due to predictive maintenance and automated workflows

  1. Scalable CloudBased Infrastructure

       Goal: Have the ability to scale in line with future growth.

Result: The cloudbased infrastructure supported a 50% growth in seasonal demand without straining resources beyond the normal levels.

Challenges Faced:

  1. Resistance to Change: Workers were first resistant to new ways of doing things brought about by new technologies. Management implemented a robust change management process where employees were trained and given workshops to help in transition.
  1. Implementation Challenges: The integration of the new system into existing procedures was technically very hard. In addressing these issues, the phased implementation approach and close collaboration with the IT useful.
  1. Data Security: Running a cloudbased system is a challenge as it may pose data safety. Encryption and regularly conducting audits are strong security measures that have been taken in running the safe avenues for the data.

Successes:

  1. Higher Efficiency: New SCM system supported by realtime analytics increased the operational efficiency of the organization by 40%. The time taken for processing orders has decreased by 83%, while the handling of inventory has been optimized.
  1. Cost Savings: The transformation reduced the logistics costs superlatively by 20% and the excess inventory costs by 30%. These were real hard savings.
  1. Increased Competitiveness: Market positioning was now facilitated with the modernization of the supply chain. The increased competitive own strength comes through the potential ability of the organization to respond more quickly to market changes and customer requests.
  1. Scalable Growth: The company is now capable of growth of 50% without any hassle, along with performance not getting affected.

Conclusion:

The strategy of digital transformation is thus presented to the test because it has successfully addressed the issues at hand, which the organization faced, showing huge improvements in efficiency, cost savings, and scalability. The following case study traces the deep transformation of a modernized traditional supply chain that detailed how strategic implementation and change management assured a continued path toward success in a world moving so fast in a digital dimension.

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