Case Study: Copperweld reduces stock-outs and inventory by 40% with Ultra Consultants

Copperweld - Customer Case Study

Copperweld, a manufacturer of structural steel tubing with annual revenues of $200 million, was struggling with inaccurate raw material inventory levels and periodic shortages. Ultra Consultants helped address this challenge after Copperweld’s MRP system failed to provide visibility into stockouts and inventory fluctuations caused by borrowing convertible raw materials across production runs.

Ultra Consultants implemented a Raw Materials Pipeline Model using a custom application and Microsoft SQL Server, along with a Cognos-based DSS and reporting tool, to simulate future raw-material consumption and improve planning visibility. The result was a significant reduction in stock-outs, nearly 2% less scrap, and a 40% reduction in raw materials inventory.

Copperweld