Summary of the Impact
A global leader in polymer packaging solutions used ThroughPut AI’s Demand Sensing solution to unlock tremendous value across its operations, including:
- $1 million saved across 3 production facilities
- 30% reduction in lead time
- 40% of working capital freed up
- Transition from make-to-stock to make-to-order production
- Significant cutback in dead stock and waste
About the Polymer Packaging Manufacturer
This 40+ year-old innovator, part of a multinational conglomerate, is globally recognized for excellence in polymer transformation. With operations spanning five continents, the company produces advanced polymer solutions, including plastic bottles and other packaging solutions. To support aggressive growth targets, the company sought a more agile, data-driven supply chain capable of scaling without waste or inefficiency.
Key Supply Chain Challenges
1. Overproduction & Inventory Overhead
Unreliable sales forecasting led to excess production, ballooning storage costs, and locked working capital. With production lines at full capacity, expansion and innovation were stifled.
2. Long, Unpredictable Lead Times
Lack of demand visibility meant missed OTIF (On-Time, In-Full) targets and customer dissatisfaction. Seasonal swings and market volatility caused major scheduling challenges.
3. Dead Stock & Operational Waste
The make-to-stock model caused overproduction of SKUs with low or no demand. Label-specific embossing rendered excess goods unusable elsewhere, compounding inventory waste and emissions.
How ThroughPut AI Solved the Problem
1. Smarter Demand Sensing & Forecasting
ThroughPut’s AI solution ingested sales data, equipment performance metrics, and production throughput across multiple systems to identify trends, bottlenecks, and inefficiencies at a granular level.
2. From Make-to-Stock to Make-to-Order
Through precise demand forecasting, the client transitioned to a make-to-order model, enabling production based on actual demand. This significantly minimized waste, energy consumption, and storage costs.
3. AI-Powered Operational Optimization
By tracking KPIs like OEE, sales by SKU, and equipment utilization, ThroughPut AI pinpointed where overproduction occurred, predicted demand shifts, and helped restructure production scheduling with AI-driven manufacturing optimization.
Impact of ThroughPut’s Demand Sensing Solution
1. $1 Million Saved in Just 3 Facilities
With AI-based production planning and reduced inventory overhead, the client saved $1M—paving the way for potential 10X savings across 30+ plants globally.
2. 30% Reduction in Lead Time
AI-driven scheduling reduced response time to demand spikes, ensuring timely replenishment and increasing customer satisfaction.
3. 40% Working Capital Freed Up
By cutting dead stock, unused raw material, and excess finished goods, the client released working capital for growth and innovation.
4. Lower Waste, Higher Sustainability
Elimination of overproduction and reduced logistics led to lower emissions and a leaner, greener supply chain.
Why This Matters for the Polymer Packaging Industry
Polymer and plastic packaging manufacturers face growing challenges from regulatory pressure, volatile demand, and increasing competition. ThroughPut AI enables businesses to:
- Forecast demand accurately with real-time sales and throughput analysis
- Align production schedules with true market demand
- Minimize raw material and energy waste
- Rapidly adapt to market changes without costly disruptions
The ThroughPut Advantage
1. AI for SKU-Level Precision
See which SKUs are profitable, which ones are dragging margins, and how demand shifts across geographies and channels.
2. Rapid Deployment & Results in 90 Days
ThroughPut AI integrates easily with your existing ERP, MES, or WMS—delivering ROI within three months of implementation.
3. Scalable Across 30+ Facilities
The modular platform grows with your business. Scale from a pilot facility to global operations with confidence.
4. Tailored for Polymer & Packaging
Whether you’re producing bottles, caps, containers, or specialty polymer products, ThroughPut AI helps you shift from reactive to proactive production planning.
Take the Next Step
If you’re a packaging manufacturer navigating complexity, demand volatility, or excessive overheads, ThroughPut AI can deliver real-time, data-driven solutions to your biggest operational headaches.
