Resilient supply chains aren’t built in crisis—they’re built in flow.
At the Supply Chain Event Paris 2025, Hutchinson shared how it moved beyond MRP logic to orchestrate one of the largest demand-driven transformations in Europe—spanning aerospace, defense, and automotive operations on four continents.
The company’s goal was not incremental improvement. It was structural change: a unified, constraint-aware planning model that replaces forecast dependency with real-time responsiveness.
Hutchinson operates over 100 sites worldwide, supplying complex engineered materials for leading OEMs. Yet beneath that scale, each factory ran its own version of the truth—different ERPs, disconnected spreadsheets, and local firefighting to keep up with shifting demand.
The result was typical of traditional MRP: growing inventories, rising shortages, and an invisible layer of chaos between data and execution.
It wasn’t a people problem. It was a system design problem.
To regain control, Hutchinson chose Intuiflow as the backbone of a new global planning and execution framework—one built on the principles of Demand Driven MRP (DDMRP) and the Theory of Constraints.
The turning point came from a single aerospace site.
Instead of pushing materials based on forecasts, Hutchinson tested Intuiflow’s demand-driven model—one that replenishes based on real consumption and manages constraints visually.
Within months, the impact was clear:
These outcomes validated what the leadership already suspected: the issue wasn’t people or effort—it was system design.
Success at one site became the blueprint for many.
Hutchinson rolled out Intuiflow across 29 aerospace and defense factories, introducing standardized material planning, and—where complexity demanded it—finite-capacity scheduling.
Then came automotive.
Higher volumes, tighter constraints, and longer sequencing cycles required new tools. Together, Hutchinson and Intuiflow co-developed planning wheels and constraint-based scheduling modules to synchronize production at the line level.
The approach was global by design, but local in execution.
Across programs, Hutchinson has realized:
More importantly, every site now operates from the same visual logic—red, yellow, green. The result is a supply chain that reacts faster, aligns globally, and plans with confidence.
Change of this scale doesn’t come from software alone. It came from structure:
This wasn’t vendor-customer—it was co-implementation at scale.
Today, Hutchinson’s roadmap extends to 60+ sites worldwide. Each quarter, new plants go live. Each site gains visibility, speed, and calm.
Their experience proves a simple truth: Resilience isn’t achieved by forecasting better—it’s achieved by designing for flow.
See how Intuiflow enables global manufacturers to operate with resilience by design. Book a walkthrough here.