Carlisle Brake & Friction Builds a New S&OP Process with Atlas

  • www.carlislecbf.com
  • Automotive
Carlisle Brake & Friction is a leading solutions provider for high performance and severe duty brake, clutch and transmission applications. It serves world class OEM and aftermarket customers in the mining, construction, military, agricultural, motorsports, industrial and aerospace markets. Carlisle Brake & Friction seeks to provide our customers with full system solutions, “from the pedal to the wheel.”

Carlisle Brake & Friction Quick Facts:

  • Headquartered in Solon, Ohio
  • R&D centers: Solon, Ohio; Bloomington, Indiana; Pontypool, Wales; Suzhou, China; Orzinuovi, Italy
  • 11 Manufacturing facilities: U.S., China, India, Italy, Japan and Wales
  • Additional satellite sales offices in India, Netherlands, and Moscow, Russia
  • Over 2,000 Employees worldwide
  • 80+ Years of experience
  • $335M in Revenue

Challenge

Prior to implementing John Galt Solutions, no formal Sales and Operations Planning (S&OP) process existed at Carlisle Brake & Friction. The company did conduct some limited forecasting in its existing ERP system, but it did not utilize any technology to support a proper forecasting and demand planning process. Prior forecasting challenges for CBF include:

  • Limited to one forecast line per item
  • No visibility to individual customer forecasts
  • Changes were not traceable
  • Could propagate changes from top level down to items

First, CBF needed to build the right S&OP process in an effort to add value to the business and be better suppliers for its customers. Once the desired process was agreed upon, CBF’s team sought the right technology to support it.  They needed a tool that would enable a sophisticated demand forecasting process, rooted in powerful statistical techniques and with the power to grow beyond it. CBF also sought a powerful reporting engine that could track their forecast assumptions and accuracy. According to CBF, the most important part of the new S&OP process was creating a sound demand plan foundation. Without an accurate forecast and solid understanding of the demand for the company’s products, building a sales, operations and supply plan would be flawed. The forecast captures the information needed to drive execution.

Solution

Initially, CBF considered expanding the company’s current ERP system to include a demand planning module. However, the team quickly realized that it was not the right tool to support their new process, nor was it cost effective. For CBF, the Atlas Planning Suite from John Galt Solutions offered both the world’s most powerful statistical engine, but also unparalleled flexibility to grow with their expanding demand planning process. John Galt’s track record of successful implementations with CBF’s ERP system also boosted their confidence. The powerful data warehouse in the Atlas Planning Suite offered the ability to deliver data in any format needed and promised an easy and quick integration. John Galt quickly assessed the situation and deployed the Atlas Planning Suite, a flexible demand planning system that fit the S&OP process CBF created.

Benefits

With the statistical power and integrated business planning approach of the Atlas Planning Suite, CBF was able to build their S&OP process on a strong foundation. With the Atlas Planning Suite, CBF can now: • Forecast by customer and/or item • Apply changes on demand at any level of the customer or product hierarchy • Systematically identify forecast outliers • Manage by exception • Integrate with existing MRP for streamlined supply planning CBF has measured marked improvements in key S&OP metrics since implementing Atlas, including: • Increased On-Time Delivery Percentage • Fewer Backorders • Improved Forecast Accuracy • Improved Inventory Turns CBF looks forward to optimizing their demand planning and entire S&OP process going forward. Automating much of the process is a key focus in the future, enabling management by exception.