Flevy Management Insights Case Study
Packaging Procurement Strategy Redesign for Plastic Packaging Manufacturer
     Joseph Robinson    |    Procurement Strategy


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Procurement Strategy 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 Plastic Packaging Manufacturer faced challenges in optimizing its Packaging Procurement Strategy due to rising raw material costs, inefficient processes, and regulatory pressures. By overhauling its Procurement Strategy and embracing Digital Transformation, the company achieved a 15% reduction in costs, improved demand forecasting, and increased market share through sustainable solutions.

Reading time: 11 minutes

Consider this scenario: A leading plastic packaging manufacturer is hitting a wall with its Packaging Procurement Strategy, struggling to stay afloat in a market that's changing by the minute.

Raw material costs have shot up by 20%, slicing into profit margins. Fluctuating oil prices are throwing production costs out of whack, and stricter environmental regs are pushing for sustainable sourcing. Internally, the company's procurement processes are a mess and supplier relationships are anything but strategic. The mission? To revamp its packaging procurement strategy to cut costs, boost sustainability, and strengthen the supply chain.



This organization, navigating a whirlwind of market changes and regulations, is wrestling with its Packaging Procurement Strategy to balance Cost-effectiveness and Sustainability. The surge in raw material costs and the evolving environmental regulations suggest a pressing need for a more strategic approach to Procurement and Supplier Management.

Environmental Assessment

The plastic packaging industry is at a critical juncture, with increasing demand for sustainable and cost-effective solutions driven by both consumer preferences and regulatory changes.

The competitive landscape is shaped by the following forces:

  • Internal Rivalry: High due to the presence of numerous players competing on price, innovation, and sustainability credentials.
  • Supplier Power: Moderate but rising, as raw materials are subject to global supply chain disruptions and price volatility.
  • Buyer Power: High, with customers increasingly demanding lower prices and more sustainable packaging solutions.
  • Threat of New Entrants: Low to moderate, given the significant capital investment and regulatory knowledge required.
  • Threat of Substitutes: High, with ongoing innovation in biodegradable and reusable packaging alternatives.

Emergent trends include:

  • Growing demand for sustainable packaging is reshaping packaging procurement strategies, offering a chance to stand out but needing serious R&D and sourcing investments.
  • Technological advances in production processes, presenting opportunities for cost reduction and efficiency gains, but requiring significant capital expenditure.
  • Global supply chain vulnerabilities, highlighting the need for diversified sourcing strategies to mitigate risks.

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Internal Assessment

The organization possesses a strong market position and brand reputation within the plastic packaging industry but is hindered by its procurement and supply chain processes.

SWOT Analysis

Strengths include a solid market position and potential to optimize its packaging procurement strategy. Opportunities lie in leveraging technology to improve procurement efficiency and in developing more sustainable packaging solutions. Weaknesses are evident in the current procurement processes and dependency on a limited number of suppliers. Threats stem from increasing raw material costs and the rapid pace of regulatory changes.

Digital Transformation Analysis

The analysis reveals significant gaps in the adoption of digital tools for procurement and supply chain management. Implementing advanced analytics and AI could enhance demand forecasting, supplier management, and inventory optimization, leading to better decision-making and cost savings.

Value Chain Analysis

Examination of the value chain highlights inefficiencies in procurement, production, and distribution. Optimizing these areas through strategic sourcing, process automation, and logistics management can drive substantial cost reductions and improve overall operational efficiency.

Strategic Initiatives for Packaging Procurement Strategy

  • Revamp Packaging Procurement Strategy: Redefine the packaging procurement strategy to focus on total cost of ownership, sustainable sourcing, and supplier collaboration. The goal is to achieve a 15% reduction in procurement costs while enhancing sustainability practices. This initiative will require investment in procurement technology, training for procurement staff, and development of strategic supplier partnerships.
  • Invest in Digital Transformation: Implement advanced analytics and AI in procurement and supply chain operations to improve efficiency, reduce costs, and enhance decision-making. The expected value includes improved demand forecasting accuracy by 30% and inventory reduction by 20%. This will necessitate investments in technology infrastructure and skills development.
  • Develop Sustainable Packaging Solutions: Innovate in sustainable packaging to meet regulatory requirements and customer demand. This involves R&D investment, collaboration with suppliers on sustainable materials, and marketing initiatives to highlight the environmental benefits. Success in this initiative could result in a 25% increase in market share among eco-conscious consumers.

Packaging Procurement Strategy 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

  • Procurement Cost Reduction: Packaging Procurement Cost Reduction: A key metric to measure how well the new packaging procurement strategy is working.
  • Sustainability Index: Measures the environmental impact of packaging solutions, reflecting progress towards sustainability goals.
  • Supplier Collaboration Score: Assesses the strength of strategic supplier relationships, crucial for long-term success.

These KPIs offer insights into the strategic plan's effectiveness, guiding adjustments to enhance performance and achieve strategic objectives.

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Stakeholder Management

Successful implementation of strategic initiatives relies on the active involvement of both internal and external stakeholders, particularly procurement teams, suppliers, and R&D.

  • Procurement Team: Central to executing the new procurement strategy.
  • Suppliers: Key partners in sustainable sourcing and innovation.
  • R&D Department: Critical for developing sustainable packaging solutions.
  • Marketing Team: Important for communicating the sustainability message to the market.
  • Customers: Their feedback on packaging solutions influences product development.
Stakeholder GroupsRACI
Procurement Team
Suppliers
R&D Department
Marketing Team
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

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Procurement Strategy Deliverables

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

  • Enhanced Procurement Strategy Plan (PPT)
  • Digital Transformation Roadmap (PPT)
  • Sustainable Packaging Innovation Framework (PPT)
  • Supplier Collaboration Program (PPT)
  • Procurement and Sustainability Performance Dashboard (Excel)

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Revamp Procurement Strategy

The organization utilized the Kraljic Portfolio Purchasing Model to categorize and manage its procurement categories more effectively. This model, developed by Peter Kraljic, assists companies in minimizing supply vulnerabilities and making the most of their purchasing power. It was particularly relevant for this strategic initiative as it helped in identifying critical areas where procurement could be optimized to achieve cost savings and sustainability goals. The team embarked on this process:

  • Classified all procurement items into four categories: non-critical, leverage, bottleneck, and strategic, based on the analysis of supply risk and profit impact.
  • Developed specific strategies for each category, such as diversifying suppliers for bottleneck items and building strong relationships with suppliers of strategic items.
  • Implemented a dynamic review process to reassess the categorization and strategy for each procurement item annually or in response to significant market changes.

Additionally, the Resource-Based View (RBV) framework was applied to assess and utilize the company's internal capabilities in supporting the revamped procurement strategy. RBV focuses on leveraging a firm's strategic resources to achieve a competitive advantage. This approach was instrumental in identifying unique organizational strengths that could be harnessed to support strategic procurement, such as the company's existing relationships with suppliers and its procurement team's expertise.

  • Conducted an internal audit to identify and classify the company’s resources and capabilities as either valuable, rare, inimitable, or non-substitutable (VRIN).
  • Aligned procurement strategy with these strategic resources, focusing on areas where the company had the strongest capabilities.
  • Launched training programs to further develop the procurement team's negotiation and supplier management skills, leveraging the company's human resources as a key strategic asset.

The combination of the Kraljic Portfolio Purchasing Model and Resource-Based View frameworks enabled the organization to significantly enhance its procurement strategy. The strategic categorization of procurement items allowed for more focused and effective management of suppliers, leading to improved sustainability practices and a 15% reduction in procurement costs. Moreover, leveraging internal capabilities ensured that the procurement strategy was not only aligned with the company's strategic resources but also contributed to a sustainable competitive advantage.

Invest in Digital Transformation

For this strategic initiative, the organization adopted the Capability Maturity Model Integration (CMMI) to systematically improve its processes for digital transformation. CMMI is a process-level improvement training and appraisal program. It was chosen because it provides a structured approach to identifying and prioritizing improvements in processes that support digital transformation, ensuring that investments in technology yield the highest returns. The organization followed these steps:

  • Assessed current digital capabilities across procurement and supply chain operations to determine the initial maturity level.
  • Identified key process areas for improvement that would have the most significant impact on digital transformation goals.
  • Developed and implemented a plan for process improvement activities, including training for staff and investment in new technologies.

In parallel, the organization applied the Diffusion of Innovations theory to facilitate the adoption of new digital tools and processes. This theory, developed by Everett Rogers, explains how, why, and at what rate new ideas and technology spread. It was instrumental in understanding and overcoming resistance to change among employees and suppliers.

  • Identified early adopters within the organization and engaged them as champions for the digital transformation initiative.
  • Utilized targeted communication and training programs to address concerns and highlight the benefits of the new digital tools.
  • Monitored adoption rates and adjusted strategies accordingly to ensure widespread acceptance and utilization of new technologies.

The application of the CMMI and Diffusion of Innovations theory to the digital transformation initiative resulted in a structured and effective approach to enhancing digital capabilities. This led to a 30% improvement in demand forecasting accuracy and a 20% reduction in inventory levels, demonstrating the value of a methodical approach to process improvement and the importance of managing change in the adoption of new technologies.

Develop Sustainable Packaging Solutions

To drive the development of sustainable packaging solutions, the organization embraced the Triple Bottom Line (TBL) framework. TBL, which focuses on social, environmental, and financial performance, was pivotal in guiding the company towards sustainability in a holistic manner. This framework ensured that new packaging solutions not only met environmental standards but also contributed positively to the company and its stakeholders. The team took the following actions:

  • Evaluated the environmental impact of current and proposed packaging solutions, aiming to minimize carbon footprint and waste.
  • Conducted social impact assessments to ensure that packaging innovations supported community well-being and sustainable sourcing practices.
  • Performed cost-benefit analyses to ensure that sustainable packaging solutions were financially viable and offered competitive advantages.

Concurrently, the organization utilized Design Thinking to foster innovation in developing these sustainable packaging solutions. Design Thinking, with its emphasis on user-centric problem solving and iterative development, was instrumental in generating creative, practical, and sustainable packaging designs.

  • Organized cross-functional workshops to ideate and prototype new packaging solutions, incorporating feedback from customers and suppliers.
  • Tested prototypes with end-users to gather insights and iteratively refine the designs.
  • Implemented a pilot launch for the most promising packaging solutions to evaluate market response and operational feasibility.

The integration of the Triple Bottom Line framework and Design Thinking into the development of sustainable packaging solutions resulted in the successful launch of innovative packaging that met environmental standards, was well-received by customers, and contributed to a 25% increase in market share among eco-conscious consumers. This outcome underscored the effectiveness of combining strategic sustainability frameworks with user-centered design methodologies in driving innovation and achieving business objectives.

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Key Findings and Results

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

  • Achieved a 15% reduction in procurement costs through the revamped procurement strategy focusing on total cost of ownership and sustainable sourcing.
  • Improved demand forecasting accuracy by 30% and reduced inventory levels by 20% following the implementation of advanced analytics and AI.
  • Launched innovative sustainable packaging solutions, resulting in a 25% increase in market share among eco-conscious consumers.
  • Developed strategic supplier partnerships and diversified sourcing strategies, enhancing supply chain resilience against global disruptions.

The strategic initiatives undertaken by the organization to overhaul its procurement strategy and embrace digital transformation have yielded significant results. The 15% reduction in procurement costs and the enhanced efficiency in supply chain operations underscore the success of these strategies in addressing the initial challenges of rising raw material costs and inefficient procurement processes. The notable increase in market share among eco-conscious consumers highlights the effectiveness of developing sustainable packaging solutions in response to market demands and regulatory pressures. However, the journey was not without its challenges. The initial resistance to digital transformation and the complexity of managing strategic supplier relationships underscore the importance of stakeholder engagement and change management in the successful implementation of new strategies. Additionally, while the focus on sustainability has paid dividends, continuous innovation and adaptation to evolving environmental regulations and consumer preferences remain critical.

For the next steps, the organization should focus on further integrating sustainability into its core business strategy, not just as a response to external pressures but as a driver of innovation and competitive advantage. This includes exploring circular economy principles to reduce waste and increase resource efficiency. Additionally, expanding the digital transformation initiative beyond procurement and supply chain operations to encompass other areas of the business can unlock further efficiencies and create new value propositions. Finally, fostering a culture of continuous improvement and agility will be crucial in maintaining the momentum of change and ensuring the organization remains responsive to market and environmental shifts.


 
Joseph Robinson, New York

Operational Excellence, Management Consulting

The development of this case study was overseen by Joseph Robinson.

To cite this article, please use:

Source: Strategic Sourcing Plan for Textile Mills in Emerging Markets, Flevy Management Insights, Joseph Robinson, 2024


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