Advanced Analytics-Driven S&OP Transformation

Business Challenge

A global chemical company operating in 30+ countries with 20+ factories managed a highly complex production system—handling ~3,000 SKUs across 200+ lines, involving multi-level processing (10+ levels), waste, and by-products.

The company faced extreme product margin variability (over 1000x between top and bottom performers), but lacked a granular, intelligent planning system to support fact-based decision-making and optimize profitability in such a dynamic environment.

Approach & Solution

We developed a digital, advanced analytics-enabled planning solution to manage the company’s vast complexity. This tool integrated with legacy systems and incorporated real-world constraints such as raw material availability, inventory levels, price dynamics, and demand forecasts.

• Smart Planning & S&OP Redesign: Built an end-to-end planning engine for multi-level production, enabling optimal SKU allocation. Re-designed the S&OP process from 3 to 18 months, backed by a revamped supply chain and agile governance.

• Digital & Scalable Enablement: Developed digital and agile capabilities to drive sustainable transformation and scale across regions and product lines.

Impact

• +12% Increase in Contribution Margin: Improved product mix decisions and resource allocation drove bottom-line impact.

• Fact-Based Decision Making: Enhanced visibility, scenario planning, and data confidence transformed S&OP from reactive to strategic.

• Scalable & Sustainable Transformation: New digital capabilities and process redesign created long-term agility and cross-functional alignment.