CASE STUDY
How Kingspan Achieved 15% On-Time Delivery Improvement with Supply Chain Analytics Dashboard
AT A GLANCE
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Client: Kingspan
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Industry: Manufacturing & Building Materials
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Location: Global Operations
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Solution: Supply Chain & Inventory Management
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Key Impact: 15% on-time delivery improvement, 20% reduction in emergency procurement
Background
The Challenge
Kingspan's supply chain teams were operating with severely limited visibility into critical operational metrics. The company relied on fragmented ERP exports that provided no unified view of open orders, overdue deliveries, or real-time stock levels across facilities. This disconnected approach created significant operational blindspots that impacted both customer service and working capital management.
The lack of integrated reporting meant plant managers had no forecasting capability to assess whether incoming orders exceeded available stock until problems materialized. Finance teams couldn't determine the financial exposure represented by capital tied up in raw materials versus finished goods inventory. Without trend insights, managers struggled to balance production and procurement decisions across sites, often resulting in either excess inventory or stockouts.
The manual process of consolidating data from multiple ERP systems consumed significant resources while still failing to provide actionable intelligence. Critical decisions about production scheduling, inventory transfers, and procurement were made reactively rather than proactively, leading to increased emergency procurement costs and delayed customer deliveries.
The Solution
GrowthBI developed a centralized Power BI reporting suite that unified Kingspan's order, inventory, and valuation data into a single source of truth. The solution empowered plant managers, finance teams, and supply chain leadership with real-time, drill-down insights across four purpose-built dashboards.
The Open Orders Dashboard provided consolidated visibility into total open orders, overdue volumes, and on-hand inventory levels. Users could drill from scheduled date to SKU to plant level, identifying exactly where delays accumulated in the supply chain. The system implemented hierarchical drill-down capabilities from year to month to week to day, with dynamic slicers for plant, product technology, and material group.
Key capabilities included:
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Inventory Dashboard: Real-time closing stock levels across all plants with week-on-week trend tracking and SKU-level breakdowns by square footage and stock value
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SKU Weekly Report: Detailed operational summaries showing stock on date, overdue orders, predicted stock levels, and automated urgency flags for items at risk of stockout
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Stock Overview Dashboard: Financial perspective on total inventory value split between finished goods, raw materials, and work-in-progress
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Predictive Analytics: Custom DAX measures forecasting stock levels based on demand patterns and open orders, with color-coded alerts for SKUs predicted to run negative within 7-14 days
Results
The supply chain analytics dashboard delivered immediate operational improvements across Kingspan's global operations. On-time deliveries improved by 15% through proactive order tracking and early intervention on potential delays. The company achieved a 10% reduction in working capital tied up in raw materials through better inventory optimization.
Emergency procurement costs decreased by 20% as the SKU risk detection system provided early warnings of potential stockouts. Plant managers could now balance production loads across sites based on real-time capacity and demand insights.
Key performance outcomes included:
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15% improvement in on-time delivery performance
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10% reduction in working capital requirements
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20% decrease in emergency procurement costs
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100% visibility across global inventory positions
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7-14 day advance warning on potential stockouts
The solution transformed Kingspan's supply chain from reactive to proactive management. Finance teams gained unprecedented visibility into capital allocation and valuation trends, enabling more strategic working capital decisions. The automated reporting eliminated hours of manual data compilation while providing superior insights for decision-making.
Looking Forward
Kingspan continues to enhance their supply chain analytics capabilities, with plans to integrate predictive demand forecasting and supplier performance metrics. The success of this implementation has positioned the company to expand analytics across other operational areas including quality management and production efficiency.
The automated insights have transformed Kingspan's supply chain from reactive to proactive management, with the company now exploring AI-driven inventory optimization models.
Want to see the technical details behind this implementation? Read our technical deep-dive to learn how we integrated ERP data with Power BI using SQL Server and custom DAX measures.