Unlocking End-to-End Supply Chain Agility with Process Mining

Challenge

A global manufacturing enterprise faced persistent inefficiencies across its supply chain — from procurement and production planning to fulfillment and logistics. Each function operated in silos using separate systems (ERP, WMS, TMS, spreadsheets), leading to fragmented visibility, poor coordination, and reactive decision-making. Efforts to optimize one part of the chain often created bottlenecks or compliance issues elsewhere.

Objective

Unify cross-functional supply chain visibility to:

Improve service levels and delivery accuracy
Reduce working capital tied up in excess inventory
Contain logistics and warehousing costs
Enable proactive, data-driven supply chain decisions without disrupting existing systems

Solution

Process mining was applied to event logs from ERP, warehouse, and transport systems to reconstruct the true end-to-end supply chain journey. The effort provided a connected view across procurement, production, inventory, and fulfillment — revealing where planning assumptions diverged from execution reality.

The analysis surfaced:

Cross-functional process maps and lead-time variances
Hidden rework loops in fulfillment, such as repeat truck rolls and misrouted deliveries
Root causes of delivery delays tied to outdated safety stock policies and poor handoff coordination
Systemic issues in supplier lead time reliability and order change propagation
Opportunities to simulate improvement scenarios and predict downstream impacts
These insights helped teams make faster, more coordinated decisions while continuing to work within their existing systems and workflows.

Outcomes

27% reduction in end-to-end fulfillment lead times
18% improvement in on-time, in-full (OTIF) delivery
Significant reduction in working capital requirements through better inventory alignment
30% drop in expedited shipments due to early anomaly detection
Established a scalable model for global supply chain visibility and harmonization

*Results described on the website are based on specific engagement and may vary depending on environment and implementation.

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Unlocking End-to-End Supply Chain Agility with Process Mining

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