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The case study focuses on a leading American beverage manufacturer that faced significant challenges in its supply chain strategy due to shifting consumer preferences during and after the COVID-19 pandemic. As sales for lower-calorie beverages surged during the pandemic, the company experienced a subsequent decline in sales as restrictions eased and consumer tastes evolved. This volatility highlighted the need for a more agile and responsive supply chain capable of adapting to rapid market changes. To address these challenges, the beverage manufacturer partnered with Ernst & Young (EY) to develop a tailored, data-driven supply chain solution. The collaboration aimed to enhance the company's ability to predict consumer demand, improve operational efficiency, and invest in employee training. Over a nearly 24-month period, EY and the manufacturer implemented several key initiatives, including the installation of new aluminum packaging lines and the application of the EY Run-to-Target (RTT) Transformation Accelerator. This approach not only increased production capacity but also allowed the company to maintain operations during equipment upgrades at other facilities, thus avoiding the need for outsourcing. The results of this transformation were substantial. The company achieved a 30% reduction in changeover times across its factories and an 18% increase in throughput for bottles and cans annually. Additionally, the RTT tool enabled the company to effectively serve over 300 wholesalers, distributors, and retailers, filling millions of cases more efficiently each year. The workforce engagement reached 100% through the implementation of Procter & Gamble’s Integrated Work System (IWS), which aligned employee efforts with the company’s operational goals. As a result, the beverage manufacturer is now operating at full capacity across 50 states, with improved efficiency and reduced interruptions in production, positioning itself as a national industry leader ready to meet evolving consumer demands.
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