Explore our case studies to see how organizations achieve operational excellence with our business model and better supply chain performance through our workshops.
Each in-depth case study shows real-world challenges, the implementation of demand-driven solutions like DDMRP in action, and the tangible results, including cost reductions from our proven approach, inventory optimization strategies from our workshops, and performance improvements powered by our expertise.
Executive Summary: This case study examines Wipaire’s journey to overcome traditional production planning and execution challenges through the adoption of Demand Driven Material Requirements Planning (DDMRP). By shifting from a reactive, time-phased system to a demand-driven approach focused on decoupled buffers and strategic priorities, Wipaire achieved significant improvements in key operational metrics, including on-time delivery, fill rate, and inventory reduction, while enhancing responsiveness to customer demand.
The Challenge (Prior State): Before implementing DDMRP, Wipaire faced several common manufacturing challenges:
Before DDMRP, Wipaire suffered from inefficient, reactive planning. Their quarterly float production planning was rigid and manual, relying on large TimePhase reports (250-300 pages, run multiple times). Daily operations were driven by immediate complaints (“squeakiest wheel”) and rigid due dates, leading to conflicting priorities, significant job backlogs (e.g., 2 weeks behind), low On-Time % (40%), poor Fill Rate % (25%), and high inventory levels ($10.5M).
The Solution (DDMRP Implementation):
Wipaire adopted DDMRP, fundamentally changing their approach. They integrated DDMRP for key parts, monitored via a dashboard, and used MRP to supply DDMRP buffers. Execution priorities were redefined, now driven by a clear hierarchy: Job Priority Code (AOG, Urgent), Stock Out status (visualized with RED/YELLOW alerts), On Hand Buffer Status, and finally Operation Due Date. A key principle adopted was viewing inventory as an asset and proactively stocking based on historical consumption, along with emphasizing communication for demand spikes.
The Results (Current State & Outcomes):
The DDMRP implementation yielded impressive results:
Lessons Learned:
Wipaire’s experience highlighted the importance of being “roughly right” over “precisely wrong” with master data, recognizing the benefit of decoupled lead times, and continuously modeling and adjusting for variability. They learned to question conventional metrics that might drive conflict, instead focusing on buffer status for better decision-making.
Executive Summary
JELD-WEN, a $4.3B global manufacturer of doors and windows, faced massive operational inefficiencies: 750,000 past-due sold units, fragmented planning processes, and dangerously low supplier OTIF performance. With no forecast, no space, and no functional MRP, they turned to Demand-Driven MRP (DDMRP). Through a phased, Excel-based rollout, they radically transformed their supply chain—cutting past-due orders by 95%, increasing OTIF to 90%, and centralizing control across 16 sites.
The Challenge (Prior State)
JELD-WEN’s supply chain was operating in survival mode:
750,000+ past-due units on customer orders
Supplier On-Time In-Full (OTIF) under 35%
No raw material forecasting or standard replenishment processes
Undertrained planners and fragmented local management
No MRP functionality in the ERP; planning was done via spreadsheets and email
Factories were space-constrained, BOMs were bloated, and SKU counts were out of control
The objective was clear: get the right parts to the right place at the right time—without forecasting and without space for excess inventory.
The Solution (DDMRP Implementation)
JELD-WEN chose DDMRP for its low cost, minimal training requirement, and speed to impact. Implementation included:
Building a manual DDMRP system in Excel to test replenishment logic
Conducting multi-day workshops for planners and operations teams
Centralizing inventory control across 16 manufacturing sites
Cleansing data and validating planning parameters
Launching structured cadence tools like Immediate Demands® and RedDot® escalation
Rolling out a sustainable management system and playbook tailored to different use cases
This lean, targeted approach allowed them to move quickly without waiting for ERP upgrades.
The Results (Current State & Outcomes)
JELD-WEN’s results speak for themselves:
Past Due Sold Units: Reduced by 95% (750,000 → 37,500)
Supplier OTIF: Increased from 35% to 90%
Stock Positions Under Central Control: Expanded 5x (15,000 → 75,000)
Centralized Planning Sites: Grew from 3 to 16
Planning Accuracy (TIRA): Jumped from 35% to 72%
Factories gained back space. Buyers became engaged decision-makers. Inventory now flows based on real demand—replacing guesswork with clarity.
Lessons Learned
Empower planners—they’re the ambassadors of change
Start small: Prove value before scaling
Connect the dots to financial outcomes to fund further improvements
Use a structured management system to weather volatility
Data accuracy is non-negotiable—garbage in, garbage out
Keep training alive: DDMRP success depends on continual learning and leadership buy-in
Conclusion
With no forecast, no extra budget, and no modern planning system, JELD-WEN still transformed its supply chain using Demand-Driven principles. Their operational turnaround demonstrates that clarity, speed, and performance are possible—even in the most constrained environments—when you stop forecasting and start flowing.
