Case Study: Asian Paints achieves increased productivity and $720,000 cost savings with Blue Yonder Factory Planner

Increased Productivity through Automation

Asian Paints’ decorative division, which manages more than 1,600 standard SKUs plus numerous made‑to‑order formulations, faced highly variable monthly and seasonal demand and complex production routing across multiple plants and suppliers. The company needed a more sophisticated supply‑chain approach to reduce manual planning, lower inventory and safety stock, and improve service levels and overall productivity.

By deploying Blue Yonder’s Factory Planner and distribution planning capabilities, Asian Paints automated advanced master planning—optimizing production locations, material alternates, capacity and inventory across the network. The initiative cut finished‑goods days from 56 to 30, saved $720,000 by eliminating unnecessary production, reduced lost sales by 0.3%, and achieved 90%+ SKU service levels at the location level, while improving cash flow and debt‑to‑asset metrics.

Asian Paints