Supply Chain Planning & Replenishment
A unified, data-driven Planning, Forecasting & Replenishment system for one of the world’s largest confectionery manufacturers.
Client
Our client is an international company and one of the world’s largest confectionery manufacturers. Products are made at seven plants and distributed through a network of distribution centers to thousands of retail points of sale—from large supermarkets to small local stores. The company’s brands are familiar to everyone and have long been part of everyday life for millions of people.
The Problem
The company wanted to gain full visibility and control over its entire supply chain — from production planning to store delivery — based on data.
The first step was connecting data from distributors and large retail partners — sales volumes, product mix, timing, and performance across every point of sale. This information became the backbone of production planning, guiding adjustments in manufacturing volumes and raw material procurement.
The scale quickly became overwhelming — thousands of SKUs, each with a limited shelf life. Even a small forecasting error meant either excess stock that had to be written off or empty shelves in stores. Manually processing that much data was no longer realistic, so planners relied only on a fraction of what was available, leaving the rest of the information untapped.
The company needed a single digital platform to connect sales analytics, production, and logistics — making it possible to manage the entire process through one continuous flow of data.
The Solution
To deal with the increasing flow of data and make planning more accurate, a system for collaborative planning, forecasting, and replenishment was introduced. It brings together information from across the supply chain — from factories to store shelves — helping the manufacturer and retailers plan sales and deliveries using shared data.
The system combines data from major retailers with the company’s own production data. Everything comes together in one place — from store shelf information and merchandiser reports to warehouse and distribution center inventories, factory data, and both actual and forecasted sales.
The system is connected to the company’s internal ecosystem — including the production planning platform and corporate SharePoint. Users sign in through Active Directory, using their regular work accounts, which makes access simple and secure.
Integration with SAP is planned next, which will make data exchange even faster and more seamless.
Dashboard with KPIs
KPI Dashboard serves as a strategic management tool that brings together the company’s key performance indicators — Service Level, Case Fill Rate, and OTIF performance. It gives managers and analysts a clear overview of the entire supply chain and helps them make timely, data-driven decisions to maintain high delivery reliability and customer satisfaction.
Open Orders
serves as the central workspace for sales and distribution. The module helps teams track all open and confirmed orders, see how workload is distributed across regions and distribution centers, and adjust priorities to keep the process running smoothly. As a result, operations stay balanced and order performance remains high.
Virtual Stock
Virtual Stock module is mainly used by merchandisers. It highlights products that are still listed in the system but no longer on the shelves. This makes it easier to spot inventory errors, plan shelf layouts, and minimize revenue losses caused by out-of-stock situations.
Out-of-Stock & Delta ISA–OSA
The Out of Stock and Delta ISA–OSA modules are designed for monitoring actual product availability on store shelves. They help identify cases where products are available in the warehouse but not yet displayed in stores, allowing teams to eliminate gaps between warehouse inventory and on-shelf availability.
Machine Learning Models
The module is built on machine-learning algorithms and includes several models for different scenarios. The baseline model forecasts demand for more than 300 product categories across all customers and warehouses three weeks in advance, while the promo model is applied during promotional periods when demand patterns become less predictable
Limited Shelf-Life Management
The system also includes a component for managing products with a limited shelf life. It identifies such items, estimates their volumes, and supports decision-making — whether to increase discounts, donate the goods, or write them off as they approach expiration.This helps minimize losses and ensures transparency throughout the process.
Forecast & Sales Analysis
5. Forecast Analysis supports demand forecasting and sales planning.
Results
The new Planning, Forecasting & Replenishment (PFR) system has transformed the company’s supply chain visibility. It now provides a clear, real-time view of product movement — from factory to store shelf.
More than 600 employees actively use the system, and adoption continues to grow. Over three years of operation, the solution has delivered measurable impact, including an ROI of 354%.
Products are now more consistently available on shelves, Out-of-Stock situations have reduced significantly, customers can reliably find their favorite brands, retailers benefit from stable deliveries, and the company enjoys improved visibility and smoother operations.
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