Interview with Shanaka Jayasinghe: Mastering S&OP and IBP for Manufacturing Resilience and Competitiveness

Interviewer: We're here with Shanaka Jayasinghe to dive deeper into how manufacturers can significantly enhance their competitive edge through effective Sales and Operations Planning (S&OP) and Integrated Business Planning (IBP). Shanaka, with your extensive expertise, can you provide more tangible insights into how these strategies fortify manufacturers, especially in challenging economic climates?

Shanaka Jayasinghe: Certainly. In today's fast-evolving and often unpredictable market, manufacturers need robust and responsive planning processes. S&OP and IBP are not just about balancing demand and supply; they're strategic frameworks that, when executed with precision and depth, can transform a manufacturer's responsiveness, efficiency, and ultimately, their market position.

Expanding on the Bullwhip Effect

Interviewer: Let's start with the bullwhip effect. How does it manifest in manufacturing, and what tangible steps can S&OP and IBP take to mitigate its impact?

Shanaka Jayasinghe: The bullwhip effect in manufacturing can cause drastic fluctuations in inventory levels, production schedules, and capacity planning — all leading to inefficiency and increased costs. Effective S&OP and IBP counter this by enhancing demand visibility and improving communication across the supply chain. For instance, by integrating market intelligence, consumer trends, and real-time sales data into planning models, manufacturers can better predict and respond to demand changes, dampening the oscillations caused by over or under-reacting to market signals.

Robust Demand Planning and Supply Technologies

Interviewer: You mentioned technologies like Kinaxis and GAINS Systems as enablers. Can you provide specific examples of how these technologies have driven S&OP and IBP success?

Shanaka Jayasinghe: Absolutely. Let's take Kinaxis, for instance. One manufacturer used Kinaxis to integrate their demand planning across multiple regions, leading to a unified view of global demand. This integration allowed them to adjust production schedules proactively, reduce excess inventory, and improve fill rates. Similarly, GAINS Systems might be used to optimize inventory levels dynamically, considering factors like lead time variability and service level targets, resulting in significant working capital reductions and service improvements.

Structuring Organisations for Effective Planning

Interviewer: How should manufacturers design their organisational structure and roles to support effective S&OP and IBP?

Shanaka Jayasinghe: An effective structure is one that promotes collaboration and accountability. For instance, having a dedicated S&OP or IBP team that spans across key functions like sales, operations, finance, and procurement can foster integrated planning and decision-making. Clear roles and responsibilities, coupled with executive sponsorship, ensure that strategic objectives trickle down into operational plans and that there's a consistent focus on achieving these goals.

Executive Sponsorship and Meeting Structures

Interviewer: Could you elaborate on the importance of executive sponsorship and meeting structures in these processes?

Shanaka Jayasinghe: Executive sponsorship is vital as it underscores the company's commitment to the S&OP and IBP processes. It ensures that these initiatives receive the necessary resources and attention and that decisions made are aligned with the strategic direction of the company. As for meetings, they should be structured to facilitate strategic discussions and actionable decisions. This means having the right data at hand, ensuring cross-functional representation, and maintaining a forward-looking agenda. Regular cadence and clear documentation of decisions and action items are also crucial.

Mastering Data for S&OP and IBP

Interviewer: You touched on the importance of item master data and other data elements. Can you discuss how manufacturers can effectively manage and utilise this data?

Shanaka Jayasinghe: Data is the lifeblood of effective S&OP and IBP. Item master data, supply chain master data, and transactional data must be accurate, accessible, and consistently updated. Manufacturers can achieve this through regular data quality audits, investing in data management tools, and fostering a culture where data accuracy is everyone's responsibility. Additionally, integrating data into user-friendly dashboards and planning tools can significantly enhance its utility, providing teams with the insights needed to make informed decisions.

Project and Change Management in Implementations

Interviewer: Finally, what role do project management and change management play in implementing S&OP or IBP?

Shanaka Jayasinghe: These are critical. Project management ensures that the implementation is methodical and aligned with objectives, timeframe, and budget. It involves detailed planning, resource allocation, and risk management. Change management, on the other hand, focuses on the people aspect — preparing, equipping, and supporting individuals to successfully adopt new processes and systems. It's about communication, training, and ongoing support. Together, they ensure that S&OP and IBP implementations are not just technically successful but also embraced and sustained by the organization.

Interviewer: Your insights today have been incredibly comprehensive, Shanaka. Thank you for sharing your deep knowledge and practical advice on S&OP and IBP for manufacturers.

Shanaka Jayasinghe: It's been my pleasure. Remember, S&OP and IBP are about more than just planning; they're about creating a resilient, agile, and competitive manufacturing operation. With the right approach, technology, and commitment, they can drive remarkable improvements and set manufacturers on a path to sustained success.

Optimising FMCG Supply Chain Design: Driving Efficiency and Competitive Advantage

The fast-moving consumer goods (FMCG) sector faces unique supply chain challenges due to high product volumes, rapid turnover rates, and consumer demand for variety and quick delivery. For FMCG organisations, supply chain design is a critical factor in maintaining profitability, staying competitive, and meeting customer expectations.

Effective FMCG supply chains must balance efficiency, cost management, and flexibility while adapting to seasonal variations, shifting consumer preferences, and unpredictable market conditions. Investments in supply chain design—especially in network optimisation, warehouse layout, demand planning, replenishment technology, and integrated planning processes—are key to driving performance improvements across the production and distribution spectrum.

In this article, we will explore the benefits of optimising supply chain design for FMCG organisations, delving into the value of network design, warehouse optimisation, advanced demand planning, and the importance of Sales & Operations Planning (S&OP). Additionally, we will discuss how Trace Consultants can support FMCG companies in Australia and New Zealand to create resilient, agile, and cost-effective supply chains that improve customer satisfaction and profitability.

The Importance of Supply Chain Design for FMCG Companies

The FMCG industry operates on tight margins and high volumes, making supply chain efficiency a critical element of success. A well-designed FMCG supply chain enables companies to respond quickly to market demand, reduce costs, and manage the complexities of short product lifecycles. Supply chain disruptions, bottlenecks, or inefficiencies can have significant impacts on profitability, customer service, and market share.

Supply chain design in the FMCG sector is about ensuring that products are sourced, manufactured, stored, and distributed in the most cost-effective and efficient manner. This requires the careful coordination of manufacturing plants, distribution centres (DCs), and transportation networks to reduce lead times, optimise production cycles, and minimise inventory holding costs.

Key areas for FMCG organisations to focus on in their supply chain design include network optimisation, warehouse layout, demand planning, and S&OP. Each of these elements plays a crucial role in improving operational performance and delivering a more resilient, responsive supply chain.

1. Network Design: Optimising the FMCG Distribution Network

The foundation of an efficient FMCG supply chain is an optimised network design. Network design refers to the strategic positioning of production facilities, distribution centres, and inventory stocking points to ensure that products can be delivered quickly and cost-effectively to customers.

In the FMCG sector, network design must account for several variables, including product shelf life, regional demand, transportation costs, and production capacity. Many FMCG companies operate on a national or global scale, meaning their supply chains need to be both flexible and robust enough to adapt to varying market conditions.

Benefits of network optimisation for FMCG companies include:

• Cost reduction: By positioning DCs and manufacturing plants closer to key markets, FMCG organisations can reduce transportation costs, decrease fuel consumption, and improve sustainability.
• Improved service levels: A well-designed network allows FMCG companies to reduce lead times and improve delivery accuracy, ensuring that products are available when and where customers need them.
• Scalability and agility: An optimised network is flexible enough to respond to market changes, including seasonal demand fluctuations or new product launches, and can quickly adjust to accommodate these shifts.

For instance, a large beverage manufacturer might optimise its supply chain network by strategically placing production plants closer to high-consumption regions to reduce transportation times, minimise product spoilage, and meet customer expectations for quick delivery. This level of planning allows FMCG companies to compete in a fast-paced, demand-driven environment.

2. Warehouse Layout Optimisation: Maximising Throughput and Reducing Costs

Warehouse layout optimisation is particularly critical in FMCG supply chains, where high volumes of goods need to be processed quickly, accurately, and cost-effectively. An optimised warehouse layout ensures that products flow smoothly through the facility, from receiving to storage, order picking, packing, and shipping, reducing lead times and improving overall operational efficiency.

Key components of warehouse layout optimisation for FMCG companies include:

• Maximising storage space: FMCG companies often deal with thousands of SKUs, from raw materials to finished goods. Efficient storage solutions, such as high-density racking, vertical storage systems, and automated storage and retrieval systems (AS/RS), can maximise space utilisation and improve accessibility to high-turnover products.
• Streamlining picking and packing processes: Order picking is one of the most labour-intensive and costly processes in an FMCG warehouse. By optimising the layout—using techniques like zone picking, wave picking, or automated picking technologies—FMCG companies can minimise picking times, reduce errors, and accelerate order processing.
• Efficient product flow: In a high-volume FMCG warehouse, smooth product flow is essential to avoid bottlenecks. An optimised layout ensures that raw materials, work-in-progress goods, and finished products move efficiently through the warehouse, from receiving to outbound shipping.
• Automation: Incorporating automation technologies—such as conveyor belts, robotics, and AGVs—helps FMCG companies handle larger volumes of goods with fewer manual interventions, reducing labour costs and improving throughput.

Example: A large FMCG company might implement an automated storage and retrieval system (AS/RS) in its distribution centre to handle fast-moving consumer goods more efficiently. This system would reduce the time it takes to retrieve and ship products, improve picking accuracy, and allow the company to handle peak periods without increasing labour costs.

Warehouse optimisation not only helps improve throughput but also enhances the ability to manage complex product portfolios and maintain the high service levels demanded by FMCG customers.

3. Demand Planning and Replenishment Technology: Improving Forecast Accuracy and Reducing Waste

Demand planning and replenishment technologies are essential for FMCG companies that need to manage large, diverse product lines with short shelf lives and fluctuating demand. By investing in advanced forecasting tools and replenishment technologies, FMCG companies can better anticipate customer demand, reduce stockouts, and minimise the risk of overproduction or product obsolescence.

Key benefits of demand planning and replenishment technologies in FMCG include:

• Enhanced forecasting accuracy: Modern demand planning tools leverage historical sales data, real-time market trends, and advanced algorithms to predict demand more accurately. This allows FMCG companies to better manage inventory levels, align production schedules, and reduce waste.
• Optimised inventory levels: Accurate demand forecasting reduces the need for excess inventory, freeing up warehouse space and reducing carrying costs. For perishable goods, this is especially important, as it minimises the risk of spoilage or waste.
• Automated replenishment: Replenishment technologies automate the process of reordering stock, ensuring that inventory is always maintained at optimal levels. This reduces manual intervention and helps FMCG companies meet customer demand without stockouts.

For FMCG organisations dealing with seasonal spikes in demand—such as increased sales during holiday periods or promotional campaigns—advanced demand planning tools allow for better anticipation of these peaks, ensuring that the right amount of product is available when needed, without overstocking.

4. Sales and Operations Planning (S&OP): Aligning Manufacturing with Market Demand

Sales and Operations Planning (S&OP) is a critical process for aligning manufacturing operations with market demand. In the FMCG sector, where production cycles must respond quickly to changes in consumer preferences, S&OP helps organisations maintain the delicate balance between supply and demand.

S&OP brings together key stakeholders from across the business—sales, marketing, finance, and supply chain management—to create a unified plan that synchronises production with market forecasts, promotional activities, and sales targets.

Benefits of S&OP for FMCG companies include:

• Improved demand-supply alignment: S&OP helps FMCG organisations match production schedules with customer demand, ensuring that they are not overproducing or underproducing key products.
• Faster decision-making: With cross-functional collaboration, FMCG companies can quickly make informed decisions about product launches, pricing strategies, and promotional campaigns, while keeping supply chain constraints in mind.
• Enhanced agility: S&OP allows FMCG organisations to respond rapidly to market changes—whether it’s an unexpected spike in demand or a disruption in the supply chain—without impacting service levels.

A well-implemented S&OP process helps FMCG companies balance production efficiency with customer responsiveness, ensuring they can meet demand without holding excess inventory or missing out on sales opportunities.

How Trace Consultants Can Help FMCG Organisations in Australia and New Zealand

FMCG organisations in Australia and New Zealand face unique supply chain challenges, from managing large product volumes and navigating regional distribution networks to responding to consumer demand in real time. Trace Consultants is well-positioned to support FMCG companies in optimising their supply chain operations through expert guidance in network design, warehouse layout, demand planning, and S&OP.

Trace Consultants offers a range of services to help FMCG organisations improve supply chain performance:

• Network Optimisation: Trace Consultants helps FMCG companies design efficient, scalable distribution networks that reduce transportation costs, improve delivery speed, and enhance service levels across Australia and New Zealand.
• Warehouse Layout Optimisation: With extensive experience in warehouse design, Trace Consultants can optimise space utilisation, streamline product flow, and implement automation solutions to improve throughput and reduce costs.
• Demand Planning and Replenishment Technologies: Trace Consultants provide advanced forecasting tools and replenishment strategies that help FMCG companies manage inventory more effectively, reduce waste, and meet customer demand with precision.
• S&OP Implementation: Trace Consultants assist FMCG organisations in integrating S&OP processes, ensuring alignment between production schedules and market demand while improving cross-functional collaboration.

With deep expertise in supply chain design, Trace Consultants can help FMCG organisations in Australia and New Zealand build agile, resilient, and efficient supply chains that drive operational excellence and competitive advantage.

For FMCG companies, supply chain design is more than just an operational necessity—it’s a strategic asset that drives efficiency, cost reduction, and customer satisfaction. By investing in network optimisation, warehouse layout design, advanced demand planning, and S&OP processes, FMCG organisations can enhance their ability to meet market demand, reduce operational costs, and stay competitive in a fast-paced, ever-changing industry.

With the support of Trace Consultants, FMCG organisations in Australia and New Zealand can optimise their supply chain operations to navigate the challenges of today’s market, ensuring long-term success and profitability.

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CSLO: The Silent Enhancer of S&OP in ANZ Manufacturing

In the ever-evolving manufacturing sectors of Australia and New Zealand, companies continuously strive to stay ahead of the curve. Amidst this pursuit of excellence, constrained service level optimisation (CSLO) emerges as a pivotal aspect, often overlooked, yet integral in shaping the sales and operations planning (S&OP) landscape.

Understanding the Power of Effective CSLO Settings

CSLO, in essence, facilitates the optimal alignment of supply capabilities with market demands. By effectively setting and fine-tuning CSLO parameters, manufacturers can achieve:

• Heightened S&OP Precision: Accurate CSLO settings allow businesses to seamlessly align their sales projections with operational capabilities, paving the way for more efficient planning and execution.
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• Inventory Excellence: Through CSLO, manufacturers can avoid common pitfalls such as overstocking or stockouts, ensuring that the inventory is always aligned with the demand.
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• Optimised Production Schedules: CSLO ensures that the manufacturing processes are always in sync with market demands, ensuring smooth operations without overextension or resource wastage.

Advanced Planning & Scheduling (APS) Systems: The Technological Advantage

Modern manufacturing cannot thrive without integrating the latest technological solutions. Advanced Planning & Scheduling (APS) systems stand out in this context, offering unparalleled advantages:

• Automated CSLO Configuration: APS systems can auto-adjust CSLO parameters based on real-time data, ensuring consistent alignment with market demands.
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• Data-Driven Insights: With APS, manufacturers can gain actionable insights from historical data, enabling them to forecast future trends and adjust their CSLO settings accordingly.
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• Integrated Operations: APS solutions offer a holistic view of the entire manufacturing operation, from procurement to dispatch, allowing for better CSLO-driven decision-making.

Strategic Investments for Unprecedented Gains

Investing wisely in manufacturing operations, especially in CSLO optimisation and APS integration, can yield tangible benefits:

• Cost Efficiency: Streamlined operations, resulting from optimal CSLO settings, can significantly reduce wastage and operational costs.
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• Improved Working Capital: With better inventory and production management, businesses can optimise their capital allocation, leading to increased liquidity and better financial health.
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• Enhanced Service Levels and Availability: The ultimate aim of CSLO is to meet customer demands efficiently. Through optimal parameter settings, manufacturers can ensure timely deliveries, higher product availability, and superior service levels.

In conclusion, for ANZ manufacturers aiming to establish a robust, efficient, and customer-centric operation, understanding and optimising CSLO settings is paramount. Coupled with the power of APS technology and strategic investments, businesses can truly set themselves apart in a competitive market.

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