84%
master data made usable within 6 weeks
Improving Cash Flow Through Smarter Inventory and Supplier Cost Optimization
Industry: Oil & Gas, Sustainable Energy
Service: Manufacturing
Service: Operational Excellence
Our Client
A leading manufacturer of custom polyethylene managing complex maintenance operations, significant spare parts inventory, and high service supplier spend.
The Challenge
The client faced profitability and free cash flow challenges driven by over $17M tied up in spare parts inventory, poor SAP data structures, and limited inventory visibility. Spare parts were not classified or easily searchable, master data governance was weak, and no standard methodology existed to manage inventory levels. At the same time, service supplier costs lacked structured sourcing and negotiation processes, contributing to year over year cost and inventory increases.
Real Results Achieved Together
Within weeks, the organization transformed data visibility, reduced costs, and unlocked working capital.
$2M
Inventory reduction
10%
Cost savings
Transformation Impact
- 84% of spare parts inventory became searchable and actively managed
- 84% of master data made usable within 6 weeks
- ~$2M inventory reduction on track over 12 months
- 10% cost reduction on in-scope supplier spend
- Data enrichment completed in 6 weeks vs. typical 4–6 months
Our Approach
- Deployed AI toolkit to cleanse, enrich, and restructure ERP master data
- Enabled large-scale searchability and usability of spare parts inventory
- Implemented structured RFQ and competitive sourcing processes
- Developed spend cube and supplier rate cards to drive cost reductions
- Introduced governance frameworks and standardized inventory min/max tools
- Launched COMPASSS smart search interface for maintenance parts
- Improved decision making through enhanced data visibility and structure
Related Services
Manufacturing
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Facing Similar Challenges?
- Unlock trapped cash in inventory
- Improve supplier cost performance
- Enhance ERP data visibility and control
- Build sustainable inventory governance
Discover More Clients Results
20%
Increase in productivity
Resources Mining and Processing
Transforming Mining Operations Through Predictive Analytics and Equipment Performance Improvements
A leading mining company improved mine planning efficiency, equipment utilization, and operational performance through integrated planning systems, predictive maintenance, and real-time monitoring technologies.
20%
Downtime reduction
Industrial Manufacturing
Improving OEE and Production Oversight Through Digital Transformation
A die-cast metal manufacturer improved equipment effectiveness, reduced downtime, and increased operational visibility through predictive maintenance, IoT integration, and real-time production monitoring.
20%
Operating cost reduction
Industrial Manufacturing
Resources Mining and Processing
Delivering Sustainable Mining Performance Through Operational Excellence
A mining company reduced operating costs by 20% through improvements in pit-to-plant planning, asset performance, maintenance reliability, supply chain management, and operational accountability.
15%
Operating cost reduction
Resources Mining and Processing
Reducing Mining Operating Costs Through Operational Excellence
A mining company reduced operating costs by 15% by improving pit-to-plant coordination, maintenance effectiveness, supply chain performance, and operational accountability through a high-performance operating system.
60%
Reduction in workplace accidents
Industrial Manufacturing
Resources Mining and Processing
Improving Safety Performance Through Real-Time Monitoring and Workforce Engagement
A leading mining company improved workplace safety and operational visibility through real-time monitoring systems, digital safety management tools, and targeted workforce training initiatives.
25%
Reduction in project delays
Industrial Manufacturing
Resources Mining and Processing
Building a Digitally Enabled CAPEX PMO for Better Project Performance
A major mining company implemented a centralized CAPEX PMO with digital reporting tools to improve governance, cost control, project visibility, and execution consistency across its capital project portfolio.
45K m²
Optimized factory layout (reduced from 52K m²)
Industrial Manufacturing
Restarting a Greenfield Factory Planning Process: Reassessing a Multi-Story Plant Design Under Extreme Time Pressure
Creating a solid, structured plan for the material flow of its production and validated the static forecast, enabling the factory to increase the output with the existing machinery.
$12M
Projected annual savings
Retail
Redesigning Warehouse Operations to Cut Cycle Time by 87% and Boost Throughput by 30%
Redesigned omni-channel warehouse operations, cutting order-to-ship cycle time by 87% and increasing throughput capacity by 30%.