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Driving Kingspan’s Supply Chain Efficiency with Data

  • Writer: GrowthBI
    GrowthBI
  • 7 days ago
  • 3 min read

Industry: Manufacturing & Building Materials

Solution Area: Supply Chain & Inventory Management

Client: Kingspan (Global Manufacturing Company)

Tools Used: SQL Server, Power BI


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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:

  • Fragmented ERP exports providing no single view of open orders, overdue deliveries, or stock levels.

  • Limited forecasting capability to assess whether incoming orders exceeded available stock.

  • Lack of visibility into financial exposure, such as capital tied up in raw materials vs. finished goods.

  • 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:

  • Hierarchical drill-down from Year → Month → Week → Day.

  • Dynamic slicers for Plant, Product Technology, and Material Group.

  • 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 DashboardDisplayed 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:

  • Time intelligence for week-on-week comparisons.

  • Plant-level trend charts with drillable time filters.

  • 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:

  • Custom DAX measures to forecast stock based on demand and open orders.

  • Color-coded “Urgent” flags when predicted stock < 0.

  • 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:

  • Cross-filtering by Stock Category, Plant, and Material Type.

  • Drill-through from summary to SKU detail for finance validation.

  • Export-ready tables for monthly reporting.

Business Value: Finance teams gained visibility into capital allocation and valuation trends, improving working capital efficiency.


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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 TotalValueFROM dbo.KingspanOrdersWHERE 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:

  • Proactively managed open orders and reduced delivery delays.

  • Balanced inventory across plants to align production and demand.

  • 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.

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