Case Study

Transforming Business Processes

Re-engineering Herman Millers Order Planning and Fulfillment Processes

Herman Miller
Fast Facts
Industry
Manufacturing Consumer Durables
Headquarters
Zeeland, Michigan
Description
Herman Miller works for a better world around
you with inventive designs, technologies
and related services that improve the human
experience wherever people work, heal, learn and
live. Its curiosity, ingenuity and design excellence
create award-winning products and services,
resulting in more than $1.3 billion in revenue in
fiscal 2010. Innovative business practices and a
commitment to social responsibility have also
established Herman Miller as a recognized global
company.

Business Challenge
JDA solutions are helping Herman
Miller gain market share through
a variety of means, the primary
one being reliability. Our industry
has been plagued with very poor
customer service for years. The JDA
solutions have driven reliability into
our plants and into our distribution
processes so that when a customer
orders something from us, they know
they can get it when we tell them
were going to ship it to them.
- Mark Douglas,
director of enterprise resource
planning and materials,
Herman Miller

Because of a lack of continuity in its manufacturing processes, Herman Millers

on-time deliveries to customers had eroded, dropping customer service levels.
To tackle this challenge and to get its costs in line with its revenue
Herman Miller embarked on a supply chain management initiative that would
enable the company to improve on-time shipping, increase inventory turns
and gain market share.

Business Solutions
JDA Factory Planner
JDA Supply Chain Planner

Business Benefits
Increased on-time shipping from 70 percent to 98 percent
Decreased work-in-process inventory by 50 percent
Increased business by $300 million with no additional capital investment

Herman Miller provides its customers with

complete office systems from panel and
office wall systems to desks, chairs and
paper clip holders. As a result, 80 percent of
the companys business is project-based.
Fulfilling these orders requires coordination
of Herman Millers diverse operating units.
Each of Herman Millers 10 plants was
operating according to its own individual
schedule, which was significantly eroding
on-time shipments to customers and,
therefore, customer service levels. In
addition, the companys costs were out of
line with its revenue.
We started looking at advanced planning
solutions, trying to figure out how to create
manufacturing schedules that we could hit
reliably and satisfy our customers, said
Mark Douglas, Herman Millers director of
enterprise resource planning and materials.

Why JDA?
To tackle these business challenges,
Herman Miller chose JDA Factory Planner
and JDA Supply Chain Planner because of
the solutions decision-support
architecture. We looked at all the usual
competitors, and JDA architecture and
speed and quality were just head and
shoulders over everybody else, Douglas
said.
JDA solutions enable consumer goods
companies to simultaneously optimize and
monitor inventory; reduce costs and risks
through integrated sourcing, negotiation
and procurement; and improve customer
service levels and reduce fulfillment costs
through multi-division and multi-channel
order management.

Additionally, consumer goods companies

use JDA solutions to minimize
transportation costs and increase service
levels through integrated transportation
procurement, planning, execution and
monitoring.

JDAs Contribution
Using JDA Business Release Methodology
which breaks large implementations
into smaller, more manageable projects
Herman Miller rolled out JDA Factory
Planner across eight plants. The business
releases focused on materials-feasible
schedules, capacity-based manufacturing
schedules and sequencing.
Each day, Herman Miller receives orders
from customers electronically. That
information is fed into JDA Supply Chain

Planner, which creates acknowledgements

of customer orders. JDA Supply Chain
Planner also creates capable-to-promise
quotes on the entire order throughout the
day. Each night, those orders are loaded
into each facilitys JDA Factory Planner,
which schedules the factory production for
the following day.
The dynamic replanning and capacity
management that JDA Factory Planner
provides allows us to maximize the
throughput of the plant, minimize the set
ups and eliminate a lot of the inefficiencies
in the manufacturing process, Douglas
said. It has enabled us to communicate in
almost real time with our suppliers. JDA
solutions are a key element of pretty much
everything we do in the manufacturing
world at Herman Miller.
Prior to implementing JDA solutions, the
process of specifying an order then
manually checking for materials and
capacity could take up to three days. Using
JDA solutions, that process occurs almost
instantaneously.

Herman Millers Results

The results that Herman Miller has achieved
since implementing JDA solutions have
been nothing short of spectacular.
Inventory turns have tripled, which is
critical for a build-to-order manufacturer.

WEB
www.jda.com
EMAIL
info@jda.com

JDA solutions have enabled Herman Miller

to reduce work-in-process inventory by 50
percent. The company has decreased its
lead times by an average of 30 percent.
As a result, Herman Miller realized a $300
million increase in business with virtually
no additional capital investment. Probably
the most incredible result was going from a
70 percent on-time shipment to a weekly
committed date to a 98 percent on-time
shipment to a daily committed date to a
customer, Douglas said. In the process of
doing that, we also eliminated about three
weeks worth of finished goods, which in
our environment is about $75 million
worth of product that is not sitting in
inventory anymore.
Those improvements have led to an
increase in both customer service and
market share for the office furniture
manufacturer. JDA solutions are helping
Herman Miller gain market share through a
variety of means, the primary one being
reliability, Douglas said. Our industry has
been plagued with very poor customer
service for years.

About JDA Software, Inc.

JDA Software Group, Inc. (NASDAQ: JDAS),
The Supply Chain Company, is a leading
global provider of innovative supply chain
management, merchandising and pricing
excellence solutions. JDA empowers more
than 6,000 companies of all sizes to make
optimal decisions that improve profitability
and achieve real results in the discrete and
process manufacturing, wholesale
distribution, transportation, retail and
services industries. With an integrated
solutions offering that spans the entire
supply chain from materials to the
consumer, JDA leverages the powerful
heritage and knowledge capital of acquired
market leaders including i2 Technologies,
Manugistics, E3, Intactix and Arthur.
JDAs multiple service options provide
customers with flexible configurations,
rapid time-to-value, lower total cost of
ownership and 24/7 functional and
technical support and expertise.

The JDA solutions have driven reliability

into our plants and into our distribution
processes so that when a customer orders
something from us, they know they can get
it when we tell them were going to ship it
to them, said Douglas.

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