Vitamin Operational Transformation: Achieving 98% Fill Rates in Nutraceutical Manufacturing

The Highlights

Zinata’s strategic partnership with a leading nutritional supplements company addressed operational complexities through incremental change. By seamlessly integrating into the organization, Zinata facilitated the implementation of new demand and planning software. Key achievements include the establishment of a corporate S&OP process, enhanced forecasting capabilities, and interim tools to sustain operations during the transition. This collaboration resulted in significant improvements, with fill rates reaching 98%, optimized inventories, and reduced material shortages. Through ongoing training and support, permanent capability was built within the organization. The success of this project underscores the strength of the consultant-client relationship, characterized by trust and collaboration.

The Headlines

98%: Order Fill Rate

The Details

Situation

A leading nutritional supplements company faced challenges due to disparate systems and processes stemming from extensive acquisitions. Poor customer fill rates and frequent material shortages were common despite high inventories. Implementing new demand and planning software was imperative, but time constraints and operational chaos posed significant hurdles.

Problem

• No consistency between internal supply chains
• Traditional planning processes were absent
• Crisis calls were business-as-usual

Solution

Zinata immersed themselves within the company, comprehending processes and building trust. They facilitated the implementation of a corporate S&OP process and a forecasting system, alongside interim Excel tools, all whilst maintaining daily operations. They devised a critical path schedule aligning technology with people and processes, offering foundational learning sessions and ongoing support. Implementation metrics tracked progress and user proficiency.

Benefit

• New software and processes enhanced efficiency
• Order fill rates reached 98%
• Inventories optimized
• Material shortages reduced

Results

Zinata’s collaborative and strategic approach transformed the operations of a leading nutritional supplements company. By integrating new demand and planning software, establishing a corporate S&OP process, and providing ongoing support and training, Zinata helped achieve remarkable improvements. The company’s fill rates soared to 98%, inventories were optimized, and material shortages were significantly reduced. This transformation highlights the value of a strong consultant-client partnership built on trust and collaboration. The long-term success achieved through this project demonstrates the importance of strategic operational changes and the lasting impact of expert guidance.