Flevy Management Insights Case Study
Supply Chain Optimization Strategy for Beverage Manufacturer in North America
     Joseph Robinson    |    Hoshin Kanri


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Hoshin Kanri to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, KPIs, best practices, and other tools developed from past client work. We followed this management consulting approach for this case study.

TLDR A mid-sized beverage manufacturing company faced rising supply chain costs and declining customer satisfaction, necessitating the implementation of Hoshin Kanri to optimize operations. The outcome included a 30% reduction in supply chain costs and a 20% improvement in order fulfillment speed, highlighting the importance of Strategic Planning and Digital Transformation in achieving operational success.

Reading time: 11 minutes

Consider this scenario: A mid-sized beverage manufacturing company based in North America is confronted with a strategic challenge requiring the implementation of hoshin kanri to strengthen its market position.

The organization is experiencing a 20% increase in supply chain costs and a 15% decline in customer satisfaction scores, attributed to both internal inefficiencies and external market pressures such as rising raw material costs and intensified competition. Additionally, the company is grappling with the impacts of global trade tensions, which have disrupted its supply chain, leading to inconsistent supply quality and delays. The primary strategic objective of the organization is to optimize its supply chain operations to reduce costs, improve customer satisfaction, and enhance competitive advantage in the North American market.



Despite the proven resilience of the beverage manufacturing industry, companies are increasingly challenged by dynamic consumer preferences and supply chain complexities. A closer examination reveals that the company's current predicament may be rooted in outdated supply chain processes and a lack of agility in responding to market changes. The organization's failure to invest in technology for supply chain optimization and its reliance on traditional distribution models have limited its ability to efficiently manage inventory and fulfill customer orders promptly.

Strategic Planning

The beverage manufacturing industry is characterized by high competition and rapidly changing consumer trends. To navigate this landscape, it's critical to understand the forces shaping the competitive environment.

  • Internal Rivalry: High, due to the presence of numerous established brands and emerging niche players, all vying for market share.
  • Supplier Power: Moderate, with a few key suppliers dominating the raw materials market, giving them some leverage over manufacturers.
  • Buyer Power: High, as consumers have a wide array of choices and exhibit low brand loyalty, pushing companies to innovate continuously.
  • Threat of New Entrants: Low to moderate, given the significant capital investment and brand development required to enter the market.
  • Threat of Substitutes: High, with consumers open to trying new beverage categories, such as functional drinks and plant-based alternatives.

Emerging trends in the industry include a shift towards health-conscious products, increased demand for sustainable packaging, and the adoption of direct-to-consumer sales channels. These trends present both opportunities and risks:

  • Increased demand for health-conscious products opens new product development avenues but requires significant investment in R&D and marketing.
  • Moving towards sustainable packaging is an opportunity to differentiate and align with consumer values but involves higher upfront costs.
  • Adopting direct-to-consumer channels can enhance customer relationships but disrupts traditional distribution models and requires digital capabilities.

A PESTLE analysis indicates that regulatory pressures around health and sustainability are mounting, technological advancements are accelerating, and economic uncertainties are impacting consumer spending. These factors necessitate a strategic reevaluation of operations, product portfolio, and market approach.

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Internal Assessment

The company's internal capabilities are a mix of strengths and weaknesses. It possesses a strong brand reputation and a loyal customer base in certain segments, but it is hindered by outdated supply chain processes and a slow response to market trends.

Benchmarking Analysis against industry leaders reveals gaps in supply chain efficiency, digital marketing strategies, and product innovation. These gaps are impacting the company's ability to compete on cost, speed to market, and product relevance.

The RBV Analysis highlights the company's strong distribution network and established brand as key resources. However, its underinvestment in technology and innovation limits its competitive advantage.

The Core Competencies Analysis suggests that the company needs to develop new competencies in supply chain management, digital marketing, and sustainable product innovation to remain competitive in the evolving beverage industry.

Strategic Initiatives

  • Implement a Digital Supply Chain Transformation: This initiative aims to leverage technology to streamline operations, reduce costs, and improve responsiveness to market changes. The intended impact is to enhance efficiency, agility, and customer satisfaction. Value creation will stem from reduced operational costs and improved market responsiveness. Required resources include technology investment, training, and process reengineering.
  • Develop Health-Focused Beverage Lines: Launch new products that cater to the growing consumer demand for healthy and functional beverages. This initiative is expected to open new market segments and drive revenue growth. Value will be created through product differentiation and tapping into emerging consumer trends. Resource requirements include R&D, marketing, and distribution channel expansion.
  • Adopt Sustainable Packaging Solutions: Transition to eco-friendly packaging options to align with consumer values and regulatory trends. This initiative will differentiate the brand and potentially reduce long-term packaging costs. Value creation arises from brand enhancement and regulatory compliance. Resources needed include investment in sustainable materials and packaging design.
  • Enhance Direct-to-Consumer (DTC) Capabilities using Hoshin Kanri: This strategic initiative involves aligning organizational efforts towards building a robust DTC channel. The intended impact is to improve customer engagement, collect valuable consumer data, and increase margins. Value creation comes from direct customer relationships and improved margins. This will require investments in e-commerce platforms, digital marketing, and customer service enhancements.

Hoshin Kanri Implementation KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


What you measure is what you get. Senior executives understand that their organization's measurement system strongly affects the behavior of managers and employees.
     – Robert S. Kaplan and David P. Norton (creators of the Balanced Scorecard)

  • Supply Chain Efficiency: Measured by reduced lead times and inventory levels, indicating successful supply chain optimization.
  • Market Share Growth in Health-Focused Segments: An increase in market share will reflect the successful introduction and consumer acceptance of new health-focused products.
  • Sustainable Packaging Adoption Rate: The percentage of products using sustainable packaging, measuring the progress towards sustainability goals.
  • DTC Sales Growth: An increase in sales through DTC channels, reflecting the success of direct engagement strategies and platform enhancements.

These KPIs will provide insights into the effectiveness of strategic initiatives, enabling timely adjustments and highlighting areas for further focus. Monitoring these metrics closely will ensure alignment with strategic goals and market demands.

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Hoshin Kanri Deliverables

These are a selection of deliverables across all the strategic initiatives.

  • Supply Chain Optimization Roadmap (PPT)
  • New Product Development Plan (PPT)
  • Sustainable Packaging Initiative Report (PPT)
  • Direct-to-Consumer Strategy Framework (PPT)
  • Digital Transformation Financial Model (Excel)

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Digital Supply Chain Transformation

The strategic initiative to digitally transform the supply chain was underpinned by the application of the SCOR Model (Supply Chain Operations Reference model). The SCOR Model provided a comprehensive framework for evaluating and improving supply chain performance across five primary areas: Plan, Source, Make, Deliver, and Return. This model was instrumental because it offered a universal language for the supply chain process and a framework for supply chain improvement, which was crucial for identifying inefficiencies and areas for digital enhancement. The organization proceeded with the following steps:

  • Assessed the current state of the supply chain across the SCOR model's five dimensions to pinpoint bottlenecks and inefficiencies.
  • Identified specific digital technologies that could address these inefficiencies, such as AI for demand forecasting (Plan) and IoT for real-time inventory tracking (Source and Deliver).
  • Implemented pilot projects in the most critical areas to test the effectiveness of these technologies before a full-scale rollout.

Additionally, the Value Stream Mapping (VSM) technique was utilized to visualize and understand the flow of materials and information as products make their way through the supply chain. This visualization was crucial for pinpointing waste and delays in the process, making it a perfect complement to the SCOR model in driving the digital transformation initiative. The organization took the following steps:

  • Mapped out the entire supply chain process from supplier to customer delivery, highlighting all steps and identifying non-value-added activities.
  • Engaged cross-functional teams to analyze these maps and brainstorm digital solutions to streamline operations, such as automating manual data entry points.
  • Re-mapped the proposed future state of the supply chain incorporating digital technologies, to serve as a blueprint for the transformation process.

The results of implementing these frameworks were transformative. The organization witnessed a 30% reduction in supply chain costs and a 20% improvement in order fulfillment speed. Moreover, the enhanced visibility across the supply chain led to better decision-making and more agile responses to market changes, thereby significantly boosting customer satisfaction.

Develop Health-Focused Beverage Lines

For the strategic initiative of developing health-focused beverage lines, the organization leveraged the Kano Model to categorize customer preferences into must-be, one-dimensional, and delighter features. The Kano Model was particularly useful in this context to prioritize features in the new product line that would satisfy and exceed customer expectations. By understanding which aspects of the product were critical to customer satisfaction and which could surprise and delight them, the organization could focus its innovation efforts more effectively. The process involved:

  • Conducting comprehensive market research to gather customer insights on health-focused beverages.
  • Applying the Kano Model to these insights to categorize different product features and prioritize development efforts accordingly.
  • Designing the initial product line to include a mix of must-be features (e.g., low sugar content) and delighters (e.g., unique flavors or functional benefits).

Conjoint Analysis was another framework utilized to understand how customers value different attributes of the health-focused beverage products, such as taste, nutritional benefits, packaging, and price. This method allowed the organization to make informed decisions about product design and marketing strategies. The steps taken included:

  • Identifying key attributes of health-focused beverages that were important to consumers.
  • Designing and conducting a conjoint analysis survey among the target market segments.
  • Using the results to inform product development, pricing strategies, and marketing messages.

The implementation of these frameworks led to the successful launch of a new line of health-focused beverages that were well-received by the market. Sales of the new product line exceeded projections by 25% in the first year, and customer feedback highlighted the appeal of both the core and delighter features, validating the effectiveness of the Kano Model and Conjoint Analysis in guiding product development and marketing strategies.

Adopt Sustainable Packaging Solutions

In pursuing the strategic initiative to adopt sustainable packaging solutions, the organization applied the Life Cycle Assessment (LCA) framework. LCA was chosen for its comprehensive approach to assessing the environmental impacts of packaging options throughout their life cycle, from raw material extraction through manufacturing, use, and disposal. This framework was critical for making informed decisions about sustainable packaging that could meet environmental goals without compromising product quality or significantly increasing costs. The organization undertook the following steps:

  • Conducted a full LCA for current packaging materials to establish a baseline of environmental impact.
  • Evaluated alternative sustainable packaging materials and processes using LCA to compare their environmental impacts.
  • Selected the most environmentally friendly and cost-effective packaging options and initiated supplier partnerships to source these materials.

The Theory of Constraints (TOC) was also employed to systematically improve the sustainable packaging initiative's success by identifying and addressing the most significant limitations that could hinder its implementation. The focus was on constraints related to supply chain, production processes, and market acceptance. The steps taken were:

  • Identified the critical constraints that could limit the ability to adopt sustainable packaging, such as supplier availability and production process adjustments.
  • Developed targeted strategies to overcome these constraints, including investing in new machinery and forming strategic partnerships with sustainable material suppliers.
  • Monitored the initiative's progress and made continuous adjustments to address new constraints as they arose.

As a result of these frameworks' implementation, the organization successfully transitioned to sustainable packaging for 80% of its product lines within two years. This shift not only reduced the company's environmental footprint but also resonated well with consumers, leading to a 10% increase in brand loyalty and positive brand perception in the market.

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Reduced supply chain costs by 30% through the implementation of digital transformation initiatives.
  • Improved order fulfillment speed by 20%, enhancing customer satisfaction.
  • Exceeded sales projections by 25% for the new line of health-focused beverages in the first year.
  • Transitioned to sustainable packaging for 80% of product lines, resulting in a 10% increase in brand loyalty.
  • Achieved a significant positive shift in brand perception due to the adoption of eco-friendly packaging solutions.

The strategic initiatives undertaken by the organization have yielded notable successes, particularly in reducing supply chain costs and enhancing customer satisfaction through improved order fulfillment speeds. The introduction of health-focused beverage lines and the transition to sustainable packaging have not only met but exceeded expectations, contributing to increased sales and brand loyalty. These achievements underscore the effectiveness of the strategic frameworks applied, such as the SCOR Model, Kano Model, and Life Cycle Assessment, in guiding the organization's transformation efforts. However, the results were not uniformly positive across all areas. The anticipated boost in direct-to-consumer (DTC) sales growth was not explicitly mentioned, suggesting potential underperformance in this area. This could be attributed to insufficient investment in digital marketing and e-commerce capabilities or a lack of alignment between the DTC strategy and consumer expectations. An alternative strategy could have been to place a stronger emphasis on digital marketing and consumer data analytics to better understand and engage with the target market, potentially enhancing DTC sales outcomes.

Based on the analysis, the recommended next steps should focus on consolidating the gains achieved while addressing areas of underperformance. Specifically, the organization should consider further investment in digital capabilities to bolster its DTC channel, leveraging data analytics to refine marketing strategies and enhance customer engagement. Additionally, continuous innovation in product development, particularly in health-focused and sustainable offerings, should remain a priority to sustain market growth and competitiveness. Finally, the organization should undertake a comprehensive review of its digital transformation initiatives to identify and rectify any gaps or inefficiencies, ensuring that the foundation for future growth is robust and adaptable.

Source: Supply Chain Optimization Strategy for Beverage Manufacturer in North America, Flevy Management Insights, 2024

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