Analysis of cost structures in production and logistics, including the implementation of a restructuring program

Abfüllanlage in der FMCG-Branche zur Veranschaulichung einer optimierten Produktions- und Lieferkette

#CostOptimization

#Disruption

Challenge

A leading beverage manufacturer was confronted with significant inefficiencies across its supply chain. Forecast inaccuracies, fluctuating production utilization, and high inventory levels led to rising costs and declining delivery performance. At the same time, volatile raw material prices, energy costs, and complex returnable logistics put additional pressure on profitability. Existing planning and control processes were no longer capable of managing increasing product portfolio complexity and seasonal peaks. The company required a structural reset of its end-to-end supply chain to remain competitive.

Our Approach

Conducted a comprehensive end-to-end supply chain assessment (planning, production, logistics, procurement, inventory management).
Analyzed production assets, line structures, and OEE to identify cost drivers and bottlenecks.
Designed a robust restructuring program covering supply chain costs, network structure, and material flows.
Renegotiated supplier conditions and established resilient sourcing strategies.

Value Delivered

Significant reduction in supply chain complexity through clearer structures and optimized processes.

Improved delivery performance and enhanced production stability through strengthened planning and bottleneck management.

Reduced dependencies and risks through more robust sourcing and supplier strategies.

Significant improvements in warehouse and inventory management with higher availability levels.

Optimized logistics processes, including efficient returnable and empty asset management.

Increased transparency through reliable KPIs and clearly defined responsibilities.

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