Sonoco managed a complex network of divisions and plants that operated using customized and visual scheduling practices.
High inventory levels had become an issue due to standard two-week lead times, and there was no efficient way to address unique demand changes at a production level.
Dynamic scheduling requirements
The company needed a more flexible solution to efficiently schedule product plans across its dynamic manufacturing network, including honoring frozen plans and periods.
Sonoco’s largest division, Tubes and Cores, serves the paper, textile, plastic film, tape and specialty industries. It was the starting point for the new company’s scheduling initiative.
“Optimization was the driving force behind the new scheduling process,” explained the director of global business technology. “However, the ability to leverage our scheduling team’s expertise to address discrete scheduling needs was the key to the overall success of the project.” As demand changes, schedulers now can rerun schedules multiple times a day with Logility and understand the potential impact to the business. This flexibility allows the Sonoco team to adjust the schedule as needed to optimize resources.
“Logility Advanced Planning and Scheduling will carry Sonoco into the future,” said the director of global business technology. “It has quickly become part of our production best practices and gives us greater confidence in our ability to respond to dynamic customer and market changes.”
Being the largest division within Sonoco also carries the distinction of running the most complex and sophisticated manufacturing processes. Several plants support multiple divisions, and implementing a streamlined scheduling process enabled greater scheduler efficiency and effectiveness. With Logility, Sonoco has completely replaced prior scheduling technology and old, on-site communication boards. “Logility was easy to deploy and training was quick and intuitive. We went live across the entire Tubes and Cores division in just 12-18 months,” said the director of global business technology. “The confidence in the plans was immediate. The ability to optimize schedules that consider machine, personnel, tooling and inventory constraints due to dynamic demand changes has increased customer service levels and product throughput, allowing Sonoco to more effectively leverage our production assets to serve our customers.”
With Logility, Sonoco has revolutionized its scheduling process across its ever-changing manufacturing environment. “Logility knows supply chain solutions and our business,” explains the director of global business technology. “Logility invests to stay ahead of market needs and understands how those changing needs impact our business. You just don’t get that depth of supply chain planning experience with an ERP solution alone.”
With Logility, Sonoco was able to improve customer service levels, compress lead times and increase reliable product availability. It increased scheduler efficiencies and effectiveness and was able to respond quickly to dynamic customer and market needs as well as optimizing schedules based on machine, personnel, tooling and inventory constraints.