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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 lifted and consumer habits changed. 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 company 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 production efficiency, and invest in employee training. Over a nearly 24-month period, EY and the beverage manufacturer implemented several key strategies, 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 shift production seamlessly between facilities, thereby avoiding outsourcing during critical periods. The results of this transformation were quantifiable and significant. The company achieved a 30% reduction in changeover times across its factories and an 18% increase in bottle and can throughput annually. Additionally, the RTT tool enabled the company to serve over 300 wholesalers, distributors, and retailers more effectively, 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 helped align employee efforts with the company’s operational goals. Overall, the beverage manufacturer not only improved its operational efficiency but also established a more resilient supply chain that could adapt to future market demands. The ongoing commitment to employee training and engagement remains a central component of their strategy as they continue to innovate and expand their product offerings.
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