Case study / D2C consumer brand
Building the Planning and Fulfilment Backbone Behind a Growing Consumer Brand
Demand turned into RM / PM requirements, semi-finished and finished production, and 3PL fulfilment through ClickPost — with COGS visible across the process.
- Consumer brand
- RM + PM planning
- SFG → FG production
- 3PL + ClickPost
- Industry
- D2C consumer foods
- Operating model
- Planned production with SFG and FG stages
- Materials
- Raw materials (RM) + packaging materials (PM)
- Fulfilment
- 3PL + ClickPost
- Core areas
- Demand planning · RM/PM planning · Procurement · Production · Inventory · COGS
[ The Turning Point ]
Watch theTransformation Story.
Go behind the systems and see the operating decisions that shaped the transformation.
[ The operation before ]
Demand in one place.Materials in another.
Every week the same question: given what we expect to sell, what do we need to buy and make — and is the stock where it needs to be? The answer lived in spreadsheets.
- PlanDemand · Production
- Expected demandSales discussion
- Production planSpreadsheet
- BOMsSeparate sheets
- MaterialsRM · PM
- RM requirementsWorked out by hand
- PM requirementsWorked out by hand
- Stock countsPeriodic
- Ship3PL · ClickPost
- 3PL stockPartner reports
- ShipmentsClickPost
- Product costEstimated
Each week, demand is turned into RM / PM needs in spreadsheets — after the stock has already moved.
- Areas working apart
- 03
- Separate records
- 09
- Automatic shortage alerts
- 00
[ Where it broke ]
Same pouch.Nobody saw it run out.
Raw and packaging material needs were calculated outside the system that held BOMs and stock — so a critical material could fall short before anyone noticed.
The stock sheet was updated once a week.
The purchase plan still assumed the opening balance.
Nothing flagged the material crossing its critical level.
- Below the critical level — no alert raised
- Packing stops: the pouches have run out
Illustrative figures · pcs
[ How we approached it ]
From expected demandto every material.
Akhilam built the backbone from demand to fulfilment — demand translated into RM / PM requirements through multi-level BOMs, with COGS visible throughout.
- 01
Understand
Traced how expected demand became buying and making decisions each week.
- 02
Design
Demand → RM / PM requirements → SFG → FG, on multi-level BOMs.
- 03
Connect
Procurement, production, 3PL and ClickPost on the same inventory record.
- 04
Run
COGS across the process, and threshold alerts before materials run short.
What we built
- Procurement
- Production
- Multi-level BOM
- Demand planning
- RM / PM planning
- COGS
- ClickPost integration
- 3PL
- Stock threshold alerts
[ The operating journey ]
One forecast.Every material accounted for.
Follow one week’s expected demand through the new planning backbone.
Expected demand is set for the week
BOMs explode demand into RM and PM requirements against stock
A packaging material falls below its threshold — an alert is raised
Semi-finished goods are made from received raw materials
Finished goods are packed with their packaging materials
The 3PL stores the stock; ClickPost ships the order
COGS carries material and production cost to the SKU
[ Process & capability exhibits ]
How the key processesnow work — try them.
Each exhibit is interactive. The values are illustrative; the logic is how the system works.
- RMJaggery270 / 380 kgCovered
- RMRoasted peanuts210 / 260 kgCovered
- RMSesame120 / 90 kgShort by 30 kg · raise PO
- PMPouch · 50 g12,240 / 9,000 pcsShort by 3,240 pcs · raise PO
- PMCarton · 48 packs250 / 300 pcsCovered
On hand Requirement
Illustrative product and BOM. In the system the BOM, current stock and planned production drive this calculation.
Every critical material above its threshold.
Illustrative materials, stock and thresholds. Thresholds are configured per material.
- Product
- Snack pack · 50 g
- Packed
- Line 1 · 21 Sep
- Status
- At 3PL · shipping
Select any record to see its link to GD-FG-2409-07.
Illustrative batches and lots. Selecting a material lot shows which other batches used it.
- Order allocated from 3PL stockpassed
- Packed & manifestedpassed
- Picked up · ClickPostAWB generatedpassed
- In transitpassed
- Deliveredpassed
Delivered — status flows back from ClickPost to the order automatically.
Illustrative shipments.
[ Before vs after ]
What changed,line by line.
- Before: Demand discussed, not translatedAfter: Demand drives manufacturing requirements
- Before: RM / PM needs in spreadsheetsAfter: RM / PM calculated from BOMs and stock
- Before: One flat production structureAfter: SFG and FG on multi-level BOMs
- Before: 3PL and shipping outside the systemAfter: 3PL and ClickPost on central inventory
- Before: Shortages found on the packing lineAfter: Threshold alerts before materials run out
- Before: Cost per product estimatedAfter: COGS visible across the process
[ Business outcomes ]
What changed wasn't one process.It was how the whole operation runs.
- PlannedDemand translated into RM / PM and production requirements
- StructuredSFG and FG production on multi-level BOMs
- Connected3PL and ClickPost linked to central inventory
- VisibleCOGS and stock available to management
- PreparedReplenishment alerts before critical materials run short
- ScalableA backbone ready for more SKUs and channels
Outcomes are described qualitatively. Figures appear only where validated by the business.
“Placeholder for a client-approved quote on what changed in planning for growth.”
[ Go deeper ]
The ConnectedD2C Brand.
Our research and implementation perspective on demand planning, quality-gated production, 3PL and quick-commerce fulfilment, product costing and cash for growing consumer brands.
- 01Demand → materials planning
- 02Quality-gated production
- 033PL, quick commerce + margin
Business email, first name and company — nothing more.
[ Could this be your business? ]
Growing demand,guessing materials?
If several of these sound familiar, you are where this business was before one planning backbone.
- Expected sales are not turned into a material plan systematically.
- RM and PM requirements are worked out in spreadsheets.
- Semi-finished and finished stages share one flat structure.
- 3PL and shipping data sit apart from your inventory.
- You find out about a material shortage on the packing line.
[ Related capabilities ]
What made thistransformation possible.
[have a similar challenge?]
Your Business Won't Look Exactly Like This. That's the Point.
We don't implement from a template. We understand how your operation actually works, identify where value is being lost, and build the technology foundation around what the business needs next.