Flevy Management Insights Case Study
Supply Chain Optimization Strategy for Chemicals Manufacturer in Europe


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Hoshin Planning 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 top European chemicals manufacturer faced supply chain issues from rising raw material costs and declining delivery rates. They implemented Hoshin Planning and an integrated supply chain management system, resulting in a 15% cut in operational costs and a 98% on-time delivery rate. This highlights the value of Strategic Planning and continuous improvement for operational excellence.

Reading time: 11 minutes

Consider this scenario: A leading European chemicals manufacturer is facing significant challenges in its supply chain operations, necessitating a strategic overhaul guided by hoshin planning.

With a 20% increase in raw material costs and a 15% decline in on-time delivery rates over the past year, the company is grappling with both internal inefficiencies and external market pressures. Additionally, it faces stiff competition from emerging markets, further eroding its market position. The primary strategic objective of the organization is to streamline its supply chain operations to reduce costs, improve delivery reliability, and strengthen its competitive stance in the global chemicals industry.



The organization in question is confronting a critical juncture in its operational and strategic trajectory. An initial assessment suggests that the root causes of its supply chain inefficiencies may stem from outdated technology, lack of integration between procurement, manufacturing, and logistics, and an over-reliance on manual processes. These issues are compounded by external pressures from increasingly volatile raw material markets and aggressive pricing strategies by competitors.

Market Analysis

The global chemicals industry is characterized by high volatility, with fluctuating raw material costs and shifting regulatory landscapes. Rapid technological advancements and sustainability mandates are reshaping industry dynamics, making it imperative for companies to adapt swiftly to maintain competitiveness.

Examining the competitive forces reveals:

  • Internal Rivalry: The sector experiences intense competition due to the presence of numerous global and regional players.
  • Supplier Power: Suppliers wield significant power, especially for specialized raw materials, impacting cost structures and profit margins.
  • Buyer Power: Large buyers and consortiums have the leverage to negotiate lower prices, squeezing manufacturers’ margins.
  • Threat of New Entrants: High entry barriers exist due to the scale, regulatory requirements, and capital intensity, mitigating the threat somewhat.
  • Threat of Substitutes: The growing push for green and bio-based chemicals presents a substitution threat to traditional chemical products.

Emergent trends include digitalization, circular economy principles, and the shift towards bio-based and sustainable chemicals. These trends signify:

  • Digitalization in operations can significantly enhance efficiency and reduce costs, presenting both opportunities and the risk of being outpaced by more technologically advanced competitors.
  • The circular economy approach offers opportunities in waste reduction and new product lines but requires substantial investment in R&D and new technologies.
  • The demand for sustainable and bio-based chemicals is growing, opening new markets but also requiring shifts in traditional manufacturing processes.

The PEST analysis highlights regulatory pressures, especially in environmental compliance, technological advancements in manufacturing and supply chain logistics, economic fluctuations affecting raw material costs, and socio-political trends towards sustainability that significantly impact the industry.

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Internal Assessment

The organization boasts a strong product portfolio and market presence but is hindered by its outdated supply chain infrastructure and processes. These internal weaknesses directly impact its ability to react swiftly to market changes and customer demands, affecting overall competitiveness and market position.

The MOST Analysis reveals misalignments between the company’s mission to lead in the chemicals market and its strategies, which have not fully incorporated digital transformation or sustainability practices. Objectives related to cost leadership and market expansion are being compromised by operational inefficiencies and strategic oversight.

The Digital Transformation Analysis underscores the urgency for the company to adopt advanced analytics, IoT in manufacturing, and blockchain for traceability to enhance operational efficiency, reduce costs, and improve product quality. The current digital maturity level of the organization lags behind industry leaders, presenting a critical area for development.

The Gap Analysis highlights significant discrepancies between the current operational capabilities and the desired state of agility and efficiency in the supply chain. There is a clear need for investment in technology, process reengineering, and skills development to bridge these gaps.

Strategic Initiatives

  • Supply Chain Digital Transformation: Implement an integrated supply chain management system to improve visibility, efficiency, and responsiveness. The strategic goal is to reduce operational costs by 15% and improve on-time delivery to 98% within 24 months. The initiative will create value by optimizing inventory levels, enhancing demand forecasting, and streamlining logistics operations. It requires investments in IT infrastructure, software solutions, and staff training.
  • Adoption of Circular Economy Principles: Develop new products and processes based on circular economy principles to tap into the growing market for sustainable chemicals. This initiative aims to increase revenue from sustainable products by 20% over the next 5 years. The source of value creation lies in differentiating the product portfolio and accessing new customer segments. This will necessitate R&D investment, new manufacturing technologies, and marketing efforts.
  • Hoshin Planning for Strategic Alignment: Implement Hoshin Kanri to ensure strategic objectives are effectively translated into operational actions and that there is alignment throughout the organization. This initiative will enhance organizational focus on critical strategic goals and improve execution efficiency. It requires the development of a robust framework for goal setting, performance tracking, and continuous improvement.

Hoshin Planning 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 gets measured gets done, what gets measured and fed back gets done well, what gets rewarded gets repeated.
     – John E. Jones

  • Supply Chain Cost Reduction: A key indicator of efficiency gains and operational improvements.
  • On-Time Delivery Rate: Reflects the reliability and responsiveness of the supply chain.
  • Revenue Growth from Sustainable Products: Measures the success of innovation and market expansion into sustainable chemicals.

These KPIs will provide insights into the effectiveness of the strategic initiatives, highlighting areas of success and identifying where adjustments may be necessary. They will also inform ongoing strategic planning and operational adjustments.

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Stakeholder Management

Successful implementation of the strategic initiatives relies on the active engagement and collaboration of both internal and external stakeholders, including the R&D team, supply chain partners, and regulatory bodies.

  • Employees: Critical for executing the supply chain digital transformation and adopting new processes.
  • Suppliers: Partners in achieving sustainability goals and ensuring supply chain resilience.
  • R&D Team: Key to developing sustainable products and processes.
  • Regulatory Bodies: Ensure compliance with environmental and safety standards.
  • Customers: Their feedback will guide product innovation and service improvements.
Stakeholder GroupsRACI
Employees
Suppliers
R&D Team
Regulatory Bodies
Customers

We've only identified the primary stakeholder groups above. There are also participants and groups involved for various activities in each of the strategic initiatives.

Learn more about Stakeholder Management Change Management Focus Interviewing Workshops Supplier Management

Hoshin Planning Best Practices

To improve the effectiveness of implementation, we can leverage best practice documents in Hoshin Planning. These resources below were developed by management consulting firms and Hoshin Planning subject matter experts.

Hoshin Planning Deliverables

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

  • Supply Chain Optimization Plan (PPT)
  • Circular Economy Product Development Roadmap (PPT)
  • Digital Transformation Framework (PPT)
  • Sustainability Impact Assessment (Excel)

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Supply Chain Digital Transformation

The organization adopted the Value Chain Analysis framework to dissect and understand its supply chain activities better. This framework, developed by Michael Porter, is instrumental in identifying value-adding and cost-generating activities. The Value Chain Analysis was particularly useful for this strategic initiative as it enabled the company to pinpoint inefficiencies and areas where digital technologies could introduce significant improvements. The team proceeded with the following steps:

  • Segmented the company’s supply chain into primary and support activities to assess their value addition and cost implications.
  • Identified key areas within logistics, operations, and procurement that were ripe for digital optimization, such as automated inventory management and predictive maintenance.
  • Evaluated existing technologies against these key areas to determine gaps and potential digital solutions.

Additionally, the Resource-Based View (RBV) framework was utilized to assess the company's internal capabilities and resources in terms of supporting the digital transformation. This perspective was crucial for ensuring that the digital transformation initiative was not only about technology adoption but also about leveraging the company's unique strengths. The implementation steps included:

  • Conducted an internal audit to catalog available resources, including technological infrastructure and employee skills.
  • Identified strategic resources that could provide a competitive advantage in the digital transformation journey, such as proprietary data and in-house IT expertise.
  • Developed a plan to enhance these strategic resources, including upskilling programs for employees and investments in IT infrastructure upgrades.

The results from implementing these frameworks were transformative. The Value Chain Analysis illuminated critical inefficiencies and opportunities for digital enhancements that were previously overlooked. Meanwhile, the Resource-Based View ensured that the digital transformation initiative was grounded in the company's core competencies, leading to a more sustainable and competitive advantage in the market. The supply chain digital transformation initiative ultimately resulted in a 15% reduction in operational costs and a marked improvement in on-time delivery rates.

Adoption of Circular Economy Principles

For the initiative focusing on the adoption of circular economy principles, the organization turned to the Triple Bottom Line (TBL) framework. This framework, emphasizing sustainability, evaluates performance in three areas: social, environmental, and financial. The TBL framework was pivotal for this strategic initiative as it provided a holistic view of the potential impacts and benefits of adopting circular economy principles, ensuring that the company’s efforts were not only profitable but also socially responsible and environmentally sustainable. The implementation process included:

  • Assessed the environmental impact of current products and processes to establish a baseline for improvement.
  • Identified opportunities within the product lifecycle for reducing waste, reusing resources, and recycling materials.
  • Conducted cost-benefit analyses to understand the financial implications of these sustainability efforts, ensuring alignment with the TBL framework.

Simultaneously, the organization implemented the McKinsey 7S Framework to ensure that all aspects of the company were aligned with the strategic shift towards circular economy principles. This framework examines seven internal elements of an organization: strategy, structure, systems, shared values, skills, style, and staff, making it an excellent tool for managing change. The steps taken were:

  • Reviewed and adjusted the company’s strategy to include sustainability and circular economy goals.
  • Aligned organizational structure and systems to support these new strategic objectives, including the creation of cross-functional sustainability teams.
  • Implemented training programs to develop the necessary skills among staff and foster a culture that embraces sustainability.

The adoption of the TBL and McKinsey 7S frameworks significantly contributed to the successful integration of circular economy principles into the company’s operations. The TBL framework ensured that the initiative remained focused on achieving broad-based sustainability goals, while the McKinsey 7S Framework facilitated organizational alignment and change management. As a result, the company not only expanded its product line to include more sustainable offerings but also improved its overall sustainability profile, leading to a 20% increase in revenue from sustainable products.

Hoshin Planning for Strategic Alignment

To ensure strategic alignment and effective execution of its objectives, the organization embraced the Hoshin Kanri framework for this initiative. Hoshin Kanri, also known as policy deployment, is a methodical approach to strategic planning and management that ensures organizational alignment towards shared goals. It was especially relevant to this strategic initiative as it facilitated a clear translation of strategic goals into actionable plans across all levels of the company. The implementation included:

  • Identified critical strategic objectives for the organization and broke them down into specific, measurable goals.
  • Engaged cross-functional teams in the development of tactics and actions to achieve these goals, ensuring buy-in and alignment.
  • Established a robust system for monitoring progress and conducting regular reviews to adjust plans as necessary.

Alongside Hoshin Kanri, the organization applied the OKR (Objectives and Key Results) framework to set specific, ambitious goals with measurable results. This framework complemented Hoshin Kanri by adding a layer of transparency and measurability to the strategic objectives, making it easier to track progress and make adjustments. The steps undertaken were:

  • Set quarterly objectives aligned with the strategic goals identified through Hoshin Kanri.
  • Defined key results for each objective, providing clear metrics for success.
  • Implemented a tracking system to monitor these key results, fostering a culture of accountability and continuous improvement.

The combination of Hoshin Kanri and OKR frameworks proved to be highly effective in enhancing strategic alignment within the organization. This structured approach to setting, executing, and monitoring strategic objectives led to improved organizational focus and execution efficiency. As a direct result, the company experienced enhanced operational performance and a stronger alignment of day-to-day activities with long-term strategic goals, positioning it for sustained success in its competitive landscape.

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Key Findings and Results

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

  • Reduced operational costs by 15% through the implementation of an integrated supply chain management system.
  • Improved on-time delivery rates to 98%, significantly enhancing supply chain reliability and responsiveness.
  • Achieved a 20% increase in revenue from sustainable products by adopting circular economy principles.
  • Enhanced strategic alignment and execution efficiency across the organization by implementing Hoshin Kanri and OKR frameworks.

The strategic initiatives undertaken by the organization have yielded significant improvements in operational efficiency, market positioning, and financial performance. The 15% reduction in operational costs and the improvement in on-time delivery rates to 98% are particularly noteworthy, as they directly address the critical challenges of cost management and delivery reliability that the company faced. The successful adoption of circular economy principles, resulting in a 20% increase in revenue from sustainable products, demonstrates the company's ability to innovate and capitalize on emerging market trends. However, while these results are commendable, the journey towards digital transformation and sustainability is ongoing. The initial success in these areas should not lead to complacency, as the competitive landscape and technological advancements will continue to evolve. The strategic alignment achieved through Hoshin Kanri and OKR frameworks has been crucial, yet the organization must remain vigilant in monitoring, adapting, and refining its strategies to sustain its competitive edge.

Given the positive outcomes and the dynamic nature of the industry, the recommended next steps include a continuous investment in technology and innovation, with a particular focus on emerging digital and sustainable technologies. The organization should also consider expanding its efforts in stakeholder engagement, particularly with suppliers and customers, to further enhance supply chain resilience and market responsiveness. Additionally, fostering a culture of continuous improvement and agility will be critical in maintaining the strategic alignment and execution efficiency achieved thus far. Finally, regular reviews of strategic objectives and operational performance metrics should be institutionalized to ensure that the organization remains aligned with its long-term goals and is able to respond proactively to new challenges and opportunities.

Source: Supply Chain Optimization Strategy for Chemicals Manufacturer in Europe, Flevy Management Insights, 2024

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