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"Demand Solutions Forecast Management opens up a whole new world for supply chain management - better demand planning, improved inventory planning and, ultimately, increased efficiency and profits."
Source : Demand Solutions

Resources Related to Case Study: Peerless Pump:

Case Study: Peerless Pump

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Peerless Pump has been designing, engineering and manufacturing pumps for more than 80 years. Although its first pumps were used to irrigate orange groves in California, its pumps today are used for a wide spectrum of applications across the globe. Some of the tallest skyscrapers in the world rely on Peerless Pump for fire protection including the Taipei 101 in Taiwan (currently the tallest at 1,667 feet), the Sears Tower in Chicago and the Empire State Building in New York City. In addition to fire protection, its pumps serve many other industries including agriculture, process manufacturing, and the massive pumps that transport safe drinking water to our cities, to name a few. By increasing forecast accuracy through the use of Demand Solutions, the company has nearly doubled its sales over the past four years while keeping inventory levels constant – allowing Peerless to pump up its profits.

Peerless Pump manufactures most of its products at its headquarters in Indianapolis, Indiana and also has operations in Alabama, Texas and California. With each location specializing in different pumps, the company can offer a wide range of products to serve its diverse group of customers. There is no finished goods inventory; Each pump is made-to-order. To increase production and assembly efficiency, Peerless Pump’s inventory consists only of the most common components used in pump production. Prior to Demand Solutions, the company based component stock levels on historical data as it did not have the ability to accurately forecast customer demand. The lack of visibility led to a distorted demand picture that adversely affected profits.

The Turning Point

Since implementation in late 2005, Demand Solutions has unclogged the company’s profit pump. Greg Brown, Director of Sales and Operations Planning, remembers feeling slightly skeptical, yet excited when Demand Solutions along with the company’s sales managers mutually predicted a drastic increase in customer demand. Based on this forecast, the company decided to add a global supplier and to make other supply chain improvements to support the expected increase in demand.

The company uses two methods to determine customer demand: the Demand Solutions’ forecast and the sales managers’ forecast. Having the dual stream of information allows Brown to identify the possible discrepancies between the information and make better forecasting decisions. He determines the forecast accuracy of the individual methods by comparing their forecasts to actual sales – coincidently, both Demand Solutions and the sales managers have a 14 percent mean absolute percent error.

“With the same absolute forecast accuracy percentage error, we knew that the sales managers’ and Demand Solutions’ growth projections were either 100 percent right or 100 percent wrong,” says Brown with a laugh.

To Brown’s relief, the projections were accurate and Peerless Pump’s timely preparations proved to be a worthy investment as it helped the company realize its growth ambitions. “Demand Solutions has helped us almost double our business by substantially increasing our forecast accuracy and planning our inventory,” says Brown. “We have not had to increase inventory levels to support the increased business; therefore, our inventory turns have increased from six to nine on this key product line.”

Peer-fect Process

Peerless Pump uses the forecast from Demand Solutions as a basis for its discussions with its sales managers. Because the company previously could not accurately forecast customer demand, the sales force did not have an opportunity to share its valuable insights. Andrew Warrington, Vice President of Business Development, sees the firsthand results of including market intelligence into the forecast and agrees completely with Demand Solutions’ belief that people are smarter than software.

“From a sales perspective, Demand Solutions forecasts what is meaningful to us,” says Warrington. “I don’t care how complex the forecasting equations are, if they do not include human instinct and the sales forces’ knowledge, the forecast will not be right. Demand Solutions combines statistics with reality to give us a clear view of customer demand.”

Currently, Peerless Pump is in the process of replacing its old ERP system with SAP and is pleased that Demand Solutions is compatible with any ERP system because of its import/export functionality. Brown uses this functionality monthly as he exports the finalized global forecast to the company’s MRP system to drive the master production and procurement schedules.

Easy Flowing

Along with the financial benefits Peerless Pump has experienced with Demand Solutions, the planning tool has also facilitated a deeper level of collaboration within the company. The software’s flexibility and ease of use have increased the company‘s planning and decision-making efficiency.

“When management develops a new means of how they want to view a forecast report, I don’t need a programmer to reconfigure the forecast level in Demand Solutions,” says Brown. “Within a few minutes, I can create new aggregate levels myself and present the new view.”

“Demand Solutions has helped us almost double our business by substantially increasing our forecast accuracy and planning our inventory,” says Brown. “We have not had to increase inventory levels to support the increased business; therefore, our inventory turns have increased from six to nine on this key product line.”

Peerless Pump’s management also likes Demand Solutions because of the charts and graphs it offers. In the past, Brown would have to print several reports and charts to reference during meetings. Now he uses the actual Demand Solutions program in real time during teleconferences through GoToMeetings, an online service similar to Webex, which gives him the ability to display his screen to everyone in the meeting. The planning tool is intuitive and people who have never seen it can understand what is on the screen, says Brown. Being able to quickly and easily see the forecasts for each market segment and physical territories has encouraged more informed discussions about realistic opportunities and risks.

Did you know…

Peerless Pumps are used in many well known structures including:

  • Taipei 101 (Taiwan)
  • Sears Tower (Chicago)
  • Jin Mao Building (Shanghai)
  • Empire State Building (NYC)
  • Aon Centre (Chicago)
  • Bank of America Tower (NYC)
  • CN Tower (Toronto)
  • Wynn Hotel (Las Vegas)
  • Trump International Hotel (Chicago)
  • Gateway Arch (St. Louis)
  • Ferrari (Italy)
  • Panama Canal
  • Oak Ridge National Lab (Tennessee)
  • RCA Dome (Indianapolis Colts stadium)
  • Conseco Fieldhouse (Indiana Pacers arena)
  • Paul Brown Stadium (Cincinnati Bengals stadium)
  • Lucas Oil Stadium (new Indianapolis Colts stadium)
  • Several cruise ships

Its pumps range in size:

  • Smallest:
    • 4-inch diameter
    • 20 gallons per minute
  • Largest:
    • 72-inch diameter
    • 110,000 gallons per minute
 
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