How long does it take you to pinpoint the root cause of an OTIF (On-Time In-Full) failure and assess its full impact across your global supply chain?
The supply chains of large manufacturers are highly complex due to their global distribution and deep vertical and horizontal integration. In addition, external factors such as trade conflicts and wars are disrupting operations with increasing frequency and unpredictability. Still, customers expect timely deliveries of the right quantity and quality.
The root causes of OTIF failures are difficult to uncover, and even when identified, their impact across the supply chain often remains unclear. This is because many companies still rely on manual, siloed analytics that hinder both a holistic view of the supply chain delivery performance and its responsiveness when disruptions occur. Moreover, the complexity of processes and the sheer volume of process data make it difficult to pinpoint inefficiencies and cost drivers – often resulting in reactive, suboptimal decisions and missed opportunities for improvement.
Getting a Grip on Supply Chain OTIF Performance
For our customer, a global leader in electrification, connectivity, and automation, we implemented an AI-powered, Celonis-based analytics solution that delivers end-to-end transparency across the supply chain and thus enables OTIF performance optimization. By integrating data from sales, production, and procurement into intuitive dashboards, the solution provides a cross-functional and cross-system view of OTIF performance with underlying root causes and impacts. It allows the company to drive targeted, data-informed decisions and continuous improvement initiatives.
Inside the Supply Chain Analytics Cockpit
The analytics cockpit consists of seven modules, powered by an underlying AI-Layer. Each module has its own focus and empowers users to address dedicated questions or problems related to end-to-end supply chain OTIF performance.
Dashboard: OTIF Overview
The OTIF Overview dashboard delivers a near-real-time view of delivery performance across sales, production, and procurement. It provides both aggregated summary statistics and detailed insights to help teams monitor performance trends. Orders are categorized into groups such as “Too Late” or “Too Early” for easy performance segmentation. Calculations are based on configurable comparison dates and threshold settings. When critical performance thresholds are breached, AI-driven alerts can notify relevant stakeholders, enabling rapid, targeted responses.
Dashboard: Production Overview
The Production Overview dashboard supports OTIF performance analysis by dimensions like plant, material group, or order type, with trend visualizations aggregated over adjustable time intervals. Users can drill into specific sub-areas, down to individual orders for root causes and deeper insights. These capabilities are also available for the sales area and procurement area.
Network Root Cause Analyzer
The Network Root Cause Analyzer traces delays through interconnected document flows spanning sales, production, and procurement. It offers a multi-level supply chain network view, detailing order relationships and exposes where bottlenecks originate.
Network Impact Analyzer
The Network Impact Analyzer assesses how disruptions impact both upstream and downstream operations as well as supply chain participants. Once a root cause is identified, the module visualizes affected orders, customers, plants, or other network dimensions. This allows for informed, targeted actions such as order rescheduling, stakeholder notification, or resource reallocation. It ensures faster recovery from disruptions with minimal operational fallout.
Network Explorer
The Network Explorer offers an interactive, visual map of document or material flows across the supply chain. It helps users understand relationships between plants, subsidiaries, and production entities. Interdependencies can be traced, such as how a delayed production order may affect multiple customer deliveries.
Resource Utilization Analyzer
The Resource Utilization Analyzer delivers a comprehensive view of production resources within the network. It identifies bottlenecks or underutilized capacities that could be affecting OTIF performance. The module highlights capacity mismatches by linking them to specific production or planned orders.
A peek under the hood: the AI layer
The analytic cockpit utilizes three AI components to provide the user with its capabilities.
- Mapper: intelligently links documents across systems and plants, creating an end-to-end network view.
- Categorizer: dynamically assigns performance categories to each order and hence allows users to track and evaluate the OTIF performance at different levels of aggregation.
- Calculator: derives resource utilization on a daily basis by matching demand and supply for production capacities.
Impact
Using the cbs Supply Chain Analytics Cockpit, the causes and effects of supply chain anomalies can be determined within 120 seconds. This transparency empowers our customers to make rapid, informed decisions and implement impactful countermeasures. As a result, delivery delays are minimized, customers experience greater satisfaction, and avoidable operational costs are significantly reduced. These improvements can lead to an OTIF performance improvement of up to 35%.
By leveraging AI-driven supply chain analytics, manufacturers can shift from reactive troubleshooting to proactive, data-driven performance management – contact us to learn more.
