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For a Fortune 500 manufacturer of large industrial lifts, five years of double-digit growth had stretched the supply chain to its limits. With 7,500+ suppliers, 1.3 million parts, and 500 plants, disruptions were not occasional events, they were the daily operating reality. Supplier strain, fragmented communication, and no real-time view into purchase orders or inventory meant the team was always reacting late, and paying for it.
The customer deployed TADA to get ahead of disruptions before they reached the line. With real-time supplier visibility, on-the-fly scenario modeling, and structured coordination workflows replacing email and spreadsheets, the team went from days to minutes in their response to supply volatility, improving on-time delivery from 65% to 95%, cutting shipment costs by 11%, and increasing planner productivity by 23%.
Volatility was constant, but the tools to respond were not. With visibility into supplier purchase orders limited to whatever suppliers chose to share, and VMI inventory tracked through manual spreadsheet updates, the team had no reliable picture of where risk was building until it was already a problem.
By the time a planner made a decision, the underlying data had often changed. Without a current view of inventory status or supplier commitments, decisions were routinely made on stale information, driving unnecessary expedites, buffer overstock, and premium freight costs.
Coordination made it worse. Planners were managing supplier exceptions across emails, phone calls, and spreadsheets. There was no centralized platform, no shared data, and no structured process, so compiling the information needed to act on a single disruption took days, leading to higher costs.
TADA's patented Digital Duplicate® platform connected the customer's systems, data, and operational logic into a single real-time model of the supply chain, encoding not just the data, but the policies and processes behind how the operation actually runs.
With the foundation in place, TADA deployed three core capabilities:
Supplier Collaboration
Gave 7,500+ suppliers a direct channel to share purchase order status, manufacturing updates, VMI inventory, and change requests in real time, replacing email and spreadsheet-based communication with a structured, data-driven collaboration environment.
Short Sheet Management
Surfaced supplier shortfalls and constraint risks the moment they emerged, quantified their financial and operational impact across the network, and guided planners through a structured response, before production was at risk. Each facility received prioritized risk lists to direct early mitigation.
Material Tracking
Provided real-time visibility into inbound material flow across all 500 plants, giving planners early warning on coverage gaps and the ability to act before a shortage reached the line. Rebalancing recommendations helped redirect constrained parts and avoid costly production stoppages.
Before TADA, a supplier disruption triggered days of manual investigation before anyone could act. After deploying TADA, the customer's response to volatility changed fundamentally.
Detect
Supplier purchase order status, VMI inventory levels, and inbound material coverage that previously required manual outreach now arrived in real time across all 500 plants and 7,500 suppliers. Planners saw shortfalls and constraint risks as they developed, not after they had already impacted the line.
Decide
Planners could model the impact of a supplier disruption before committing to a response. Scenario planning across inventory, inbound shipments, and rebalancing options moved from a multi-day analysis to an on-the-fly capability, with every option evaluated against operational and cost tradeoffs before a decision was made.
Act
Response coordination that had run through email threads and spreadsheets shifted to structured, role-based workflows inside TADA. Planners, supervisors, and suppliers worked from the same data. Corrective actions were created, tracked, and resolved inside the platform, with supplier change requests reviewed and approved in real time.
The shift from reactive to proactive supplier management delivered measurable results across delivery performance, cost, and productivity.
