W.R. Grace & Co.

W. R. Grace & Co. is an American chemical business based in Maryland. It produces specialty chemicals and specialty materials which makes catalysts, related products and silica based and silica-alumina based materials, used in pharmaceutical/consumer, coatings, and chemical process applications.

THE CHALLENGES

• Lack of end-to-end functional integration (silos) across the supply chain
• A Global Design Model integrated across the company
• Support for global design for future roll-outs within Grace  
• Prepare the organization for global design to S/4HANA digital transformation
• Increased ROI from existing SAP investment

THE SOLUTIONS

• Supply chain transformation utilizing Reveal’s oVo^®  Methodology focused on optimizing inventory, capacity and production planning, demand management and warehouse material flows to support improving service levels
• Implement MRP across functional processes in SAP
• Develop Global Design Model to support standardardization across the organization and build a foundation for moving to S/4HANA
• Improve service and inventory levels through improvements in data quality and utilization of SAP capabilities
• Increased effectiveness of supply chain processes
• Increased product availability to support reliable order fulfillment scheduling and delivery creation
• Drive operational improvements in supply chain, production planning, materials, and distribution
• Elevate team member skills applying critical thinking, decrease manual effort, increase trust and user confidence in the system
• Drive organizational change by educating on SAP best practice and driving alignment of business rules with system settings
• Establish ownership and accountability of master data and its application 
  

THE RESULTS

• Inventory optimization:
  • Turns ratio up 32%
  • Average inventory down 13%
  • Dead stock down 14%
• Enhanced inventory management process to improve visibility
• Process efficiency improvements:
   • Red Lights down 11%
    • Overdue MRP elements down 70% 
    • Schedule attainment at 80%
• Improved buying decisions, purchasing spend and warehouse holding costs
• Optimized capacity management and improved scheduling in SAP
• Improved visibility, alignment and efficiencies reflected in KPIs
• Proven model to implement across the organization to improve operational maturity and agility
• Advanced Grace employee knowledge wealth through SAP best practice education, application, certification, and continuous improvement mindset.