Case Study: AmerCareRoyal achieves 98% fill rates and 25% lower inventory with GAINSystems

How ACR Achieved 98% Fill Rates And Reduced Inventory While Growing Sales

AmerCareRoyal (ACR), a manufacturing company serving foodservice, janitorial, sanitation, industrial, hospitality, and healthcare markets, was dealing with a complex supply network after multiple acquisitions. Different systems and replenishment approaches across business units led to stockouts, delayed deliveries, split orders, and extra transfer and expedite costs, hurting fill rates and customer satisfaction. To address these issues, ACR turned to GAINSystems for supply chain planning and optimization support.

GAINSystems helped ACR improve everyday planning first, then move into network design and facility optimization using forecasting, replenishment, and “what-if” scenario modeling. This phased approach enabled ACR to consolidate and optimize DCs without disrupting service, resulting in fill rates rising from the mid-70% range to 98%, default location fulfillment above 95%, a 27% reduction in outbound freight and warehouse expenses, and a 25% inventory reduction even as sales continued to grow.

AmerCareRoyal

Brett Barnello

Chief Supply Chain Officer