How Amorim Cork revolutionized production planning

Against a backdrop of growing operational complexity and increasing demands to respond to the market, Amorim Cork identified the need to structurally transform its planning process. With the goal of increasing decision reliability, improving customer service level, and reducing invested capital, the organization adopted an innovative approach based on advanced analytics.

Elevating planning to a new level of operational excellence

Amorim Cork, a global leader in the production and commercialization of cork solutions, launched an ambitious digital transformation program in 2016, with the implementation of an ERP across all functional areas and business units.

In the operational domain, the initial focus was on adopting standard planning and production solutions. However, the growing complexity of the production process and the need to align supply and demand made it clear that evolving to a more robust, integrated, and customer-oriented model was necessary.

It was in this context that CPA – Cork Planning Analytics was created, an advanced analytics solution developed to structurally transform production planning and sequencing.

Driving transformation and strengthening planning reliability

The project’s strategic rationale was clear: improve the existing planning solution, increase decision reliability, and strengthen customer service level.

The main challenge lay in the need to effectively align:

• Customer demand.
• The finishing unit.
• The production unit.
• And the flow of information across all areas.

The lack of full integration generated inefficiencies, excessive time consumption in planning, and high levels of safety stock.

The transformation was based on a three-phase structured approach:

1. Detailed process mapping, from distribution to production planning, identifying constraints and opportunities.
2. Definition of the future planning model, with clear requirements and an end-to-end vision.
3. Development, iterative testing, and implementation of the CPA, ensuring seamless integration with existing systems.

Actions implemented to optimize planning and sequencing

The CPA was designed as an end-to-end solution that integrates production, quality, and process control, ensuring a holistic view of the production flow.

Among the main initiatives implemented are:

• Structuring a new macro-planning model.
• Creation of new work centers and improvement of master data.
• Development of interfaces and robust analytical models.
• Implementation of an advanced sequencing module.
• Automation of previous manual planning.
• Scenario simulation to support more informed decision-making.
• Strengthening the interconnection between production and finishing units.

The sequencing module enabled optimization of production orders and maximization of installed capacity, promoting faster, more consistent, and data-driven decisions. Visibility and transparency across teams increased significantly, strengthening alignment between supply and demand.

Results that build a future of operational excellence

The implementation of CPA has  revolutionized the way planning is carried out at Amorim Cork, resulting in significant operational and financial gains:

• 91,6% reduction in macro-planning time.
• 88% reduction in the time required to create production plans.
• 23,3% reduction in raw material inventory.

In addition to the significant quantitative results, substantial qualitative improvements were also achieved:

Increased planning and sequencing reliability across units

Reduction of internal inventories

Consistent improvement in customer service levels

Reduction of capital invested in safety stock

Planning automation made it possible to free up team time, increase decision accuracy, and significantly reduce the operational effort associated with plan creation. At the same time, improved information quality and scenario simulation capability strengthened the process’s strategic robustness.

This transformation enabled Amorim Cork to evolve toward a more agile, reliable, and customer-oriented planning model. By integrating advanced analytics with a structured approach to improvement, the organization strengthened its competitiveness, reduced capital investment, and elevated service levels, positioning itself for sustained growth.

More than a technological evolution, this project represents a structural transformation at the core of operations, positioning Amorim Cork at the forefront of operational excellence and data-driven decision-making.