1. Greencore Case Study
Optimising Inventory with S&OP
Chris Chestney
Solutions Architect, Greencore Group PLC
Jonathan Ogg
Senior Consultant, TXT e-solutions Ltd
2. Agenda
• TXT Introduction
• Case Study: Greencore
• Greencore Environment and Challenges
• How these were addressed with TXT
3. Global Specialist in ‘End-To-End’ Planning &
Visibility solutions
One Single Focus: Supply Chain Planning
Deep expertise and focus in Food & Beverage,
Consumer Packaged Goods, Manufacturing,
Wholesale, Luxury, Specialty Retail and Global
Brands
Powerful, Easy to Use & Flexible Platform that
Tailors to your Business
Global Microsoft Partner
Public, Steadily Growing and Profitable
Develops, supplies and installs software
Formed
1989
People
700+
Turnover
€61.5
Customers
350+
4. Europe
Milano, IT Head Office
Barcelona, SP
Bari, IT
Chemnitz, DE
Genova, IT
Halle (Saale), DE
Leicester, UK
Lyon, FR
Paris, FR
Torino, IT
Vicenza, IT
Wynyard, UK
Americas
Toronto, CA
Atlanta, USA
Asia Pacific
Sydney,AU
Hong Kong
Singapore
5. Our Customers are our Best Credentials
Fashion & Apparel Food & Beverage Manufacturing
& Distribution
Retail
7. TXT – Advanced Planning & Execution
"TXT software combines end to end
Advanced Planning & Execution;
Advanced Demand & Supply Planning and
Production Scheduling, with execution
provided by MES, Procurement,
Warehousing, Sales Processing and
Process Control.
This provides a complete solution for
manufacturing & distribution
companies."
Procurement,
Warehouse,
Sales,
Demand
Planning
& Trade
Promotions
Advanced
Supply
Planning
Production
Scheduling
& MES
Process
Connection
10. About Greencore
• A leading manufacturer of convenience food in the UK and the US
• Strong market positions in the UK convenience food market across food to
go, chilled prepared meals, chilled soups and sauces, ambient sauces &
pickles, cakes & desserts and Yorkshire puddings
• A fast growing food to go business in the US, serving both the convenience
and small store channel and the grocery channel
• Turnover of c.£1.3 billion
• FTSE 250 listing on London Stock Exchange (GNC.L)
Tier 1 supplier to retailers
12. Business Overview
Food to Go
• No.1 manufacturer of sandwiches
• UK sites in Worksop, London (2), Northampton, Spalding &
Crosby
Prepared Meals
• Leading manufacturer of chilled prepared
meals, quiche, pasta sauce & soup
• UK sites in Kiveton, Warrington, Wisbech,
Bristol & Consett
Grocery & Frozen Foods
• No.1 manufacturer in own label cooking
sauces & pickles.
• A leading manufacturer of frozen Yorkshire puddings
• UK sites in Selby & Leeds
Cakes & Desserts
• Three distinct ‘sweet’ businesses in the UK
• Produces ambient cakes, chilled desserts for
retail customers as well as cakes and desserts
for foodservice channels
• UK sites in Hull, Taunton & Evercreech
USA
• A fast growing food to go business in the US, serving
both the convenience and small store channel and
the grocery channel
• Six sites in Newburyport (MA), Brockton (MA),
Fredericksburg (VA), Salt Lake City (UT), Chicago (IL)
and Jacksonville (FL)
Ingredients & Property
• Trilby Trading – a leading importer and distributor of
oil and fats for food processing
• Premier and United Molasses – leading importers
and distributors of molasses for animal feed and
industrial use in Ireland
• Property – management of the Group surplus
property assets
17. Current UK Planning Process Overview by Category
Food To Go
Cakes & Desserts GroceryForecastForecast ForecastForecast Forecast ForecastForecast
Demand Supply Production
Prepared Meals
Supply Plan
- MPS/MRP
- Infinite Capacity
- Bottleneck identification
Wisbech
Daily
Schedule
Warrington
Daily
Schedule
Kiveton &
Consett
Daily
Schedule
Bristol
Daily
Schedule
Manton
Wood
Daily
Schedule
Crosby
Daily
Schedule
London
(2)
Daily
Schedule
North-
ampton
Daily
Schedule
Grocery
Supply PlanSupply PlanSupply Plan
- MPS/MRP
- Finite
Capacity
- Optimised
Cost
- Balanced
Load
- MPS/MRP
- Finite
Capacity
- Optimised
Cost
- Balanced
Load
- MPS/MRP
- Finite
Capacity
- Optimised
Cost
- Balanced
Load
Supply PlanSupply Plan
- MPS/MRP
- Finite
Capacity
- Optimised
Cost
- Balanced
Load
- MPS/MRP
- Finite
Capacity
- Optimised
Cost
- Balanced
Load
Taunton
Daily
Schedule
Evercreech
Daily
Schedule
Hull
Daily
Schedule
Selby
Daily
Schedule
Leeds
Daily
Schedule
Forecast
Supply Plan
- Weekly
- Daily
- Shelf Life
Supply Plan
- Weekly
- Daily
- Shelf Life
Supply Plan
- Weekly
- Daily
- Shelf Life
Supply Plan
- Weekly
- Daily
- Shelf Life
Category Plan
- Long term view
- Infinite Capacity – what do we make where?
18. Greencore Grocery - Selby
Forecast
Supply Plan
• MPS/MRP
• Finite Capacity
• Optimised Cost
• Balanced Load
Selby
Daily Schedule
Demand Supply Production
• 2 years Demand Plan
• Collaboration with Account Management Teams
• Master Plan for Finished Goods & Critical
Components e.g. Glass
• Finite Constraints
• Maximise Labour Usage cost balanced with
Inventory levels
• Cost optimised Cycling to drive up yields
• Synchronise Production through multiple BOM
levels (up to 15)
• Optimal Changeovers to drive up yield
• MRP Integration
