CASE STUDY
Driving Kingspan’s Supply Chain Efficiency with Data
Industry: Manufacturing & Building Materials
Solution Area: Supply Chain & Inventory Management
Client: Kingspan (Global Manufacturing Company)
Tools Used: SQL Server, Power BI
Business Impact
15% improvement
in on-time deliveries through proactive order tracking.
10% reduction
in working capital tied up in raw materials.
20% cut
in emergency procurement costs via early SKU risk detection.
The Challenge
Kingspan, a global manufacturer of insulation and building materials, faced growing complexity in managing supply chain operations across multiple plants and hundreds of SKUs.
Key issues included:
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Fragmented ERP exports providing no single view of open orders, overdue deliveries, or stock levels.
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Limited forecasting capability to assess whether incoming orders exceeded available stock.
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Lack of visibility into financial exposure, such as capital tied up in raw materials vs. finished goods.
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Plant managers lacked trend insights, making it difficult to balance production and procurement across sites.
This fragmented reporting slowed decision-making and increased the risk of stockouts, order delays, and inefficient working capital utilization.
Our Solution
GrowthBI developed a centralized Power BI reporting suite that unified Kingspan’s order, inventory, and valuation data. The solution empowered plant managers, finance, and supply chain teams with real-time, drill-down insights across four purpose-built dashboards.
Dashboard Walkthrough
1. Open Orders Dashboard
Provided a consolidated view of Total Open Orders, overdue volumes, and on-hand orders.
Users could drill from Scheduled Date → SKU → Plant to identify where delays accumulated.
Power BI Functionality Used:
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Hierarchical drill-down from Year → Month → Week → Day.
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Dynamic slicers for Plant, Product Technology, and Material Group.
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What-If Parameters to model target lead times.
Business Value: Improved visibility for sales and production teams to anticipate late orders and act early.
2. Inventory Dashboard
Displayed closing stock levels across all plants (Winchester, Rockford, Mendota, Miami) with week-on-week trend tracking.
Showed SKU-level breakdowns of top contributors by FT² and stock value.
Power BI Functionality Used:
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Time intelligence for week-on-week comparisons.
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Plant-level trend charts with drillable time filters.
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Conditional formatting to flag declining stock levels.
Business Value: Enabled managers to balance production loads across sites and align with forecast demand.
3. SKU Weekly Report
Delivered a detailed SKU-level operational summary: Stock as on date, Overdue Orders, Predicted Stock, Invoiced Quantities, and Urgency Flags.
Automatically highlighted SKUs at risk of running negative within 7–14 days.
Power BI Functionality Used:
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Custom DAX measures to forecast stock based on demand and open orders.
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Color-coded “Urgent” flags when predicted stock < 0.
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Drill-through to SKU history to investigate anomalies.
Business Value: Improved procurement efficiency by identifying shortages early, reducing downtime and emergency orders.
4. Stock Overview Dashboard
Provided a financial perspective on total inventory value split into Finished Goods, Raw Materials, and WIP.
Tracked month-wise valuation trends for working capital analysis.
Power BI Functionality Used:
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Cross-filtering by Stock Category, Plant, and Material Type.
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Drill-through from summary to SKU detail for finance validation.
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Export-ready tables for monthly reporting.
Business Value: Finance teams gained visibility into capital allocation and valuation trends, improving working capital efficiency.
Technical Architecture & Process
Data Flow:
ERP Exports → SQL Server Staging → Power BI Data Model → Interactive Dashboards
SQL Model:
-- Weekly Stock and Order SummarySELECT
Plant,
SKU,
SUM(OpenOrdersFT2) AS TotalOpenOrdersFT2,
SUM(OnHandStockFT2) AS TotalOnHandFT2,
SUM(StockValueLocal) AS TotalValue
FROM dbo.KingspanOrders
WHERE WeekEnding BETWEEN @StartDate AND @EndDateGROUP BY Plant, SKU;
DAX Snippet for Overdue Order Calculation:
OverdueOrders :=
CALCULATE(
SUM(Orders[OpenOrderFT2]),
FILTER(Orders, Orders[ScheduledDate] < TODAY())
)
Conclusion
The Kingspan Manufacturing Dashboards established a single source of truth across orders, inventory, and financial stock valuation.
With Power BI’s real-time insights and SQL-based automation, Kingspan:
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Proactively managed open orders and reduced delivery delays.
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Balanced inventory across plants to align production and demand.
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Improved financial control through transparent stock valuation reporting.
The result: a data-driven supply chain that optimizes working capital, reduces costs, and strengthens delivery performance across Kingspan’s global operations.