Guardian Automotive Reduces Obsolescence Risk and Standardizes Planning with Intuiflow

Guardian Automotive is one of the few automotive suppliers in the world that manufactures both safety glass and injected plastic components (TRIM) for vehicles. In Spain, the company operates multiple sites—including a windshield plant, a plastics and coatings facility, and a national distribution and service network for repair and replacement.

To maintain its reputation for quality and responsiveness, Guardian needed a planning process as advanced as its products. But forecast-based planning made that increasingly difficult.

The Challenge: Forecast-Driven Planning in a Fast-Moving Market

Guardian’s operations faced the perfect storm of volatility:

• Short product lifecycles that made forecasts obsolete almost immediately
• High mix and long raw-material lead times, with suppliers dispersed across regions
• Large production lots driven by strict quality requirements
• Multiple planning tools, each producing different answers

The result was predictable—excess finished goods, frequent adjustments, and rising obsolescence risk.

With more SKUs reaching end of life sooner and supplier variability increasing, Guardian needed a faster, more adaptive way to plan—one that could absorb demand changes without creating costly waste.

The Solution: From Forecasts to Flow with Intuiflow

Guardian Automotive replaced forecast-driven MRP with a demand-driven planning model powered by Intuiflow (formerly Replenishment+), implemented in partnership with CMG Consultores.

The team introduced dynamic inventory buffers at both the finished-goods and raw-material levels. These buffers automatically adjust to demand variability and supplier performance, filtering noise and stabilizing production.

Instead of producing to forecast, Guardian began building lots directly from sales signals, ensuring every run was connected to real demand and reducing the risk of obsolescence.

All planning activities were unified in a single integrated tool—standardizing processes from manufacturing through distribution and improving visibility across the entire supply chain.

The Results: Stability, Speed, and Standardization

By adopting Intuiflow and Demand Driven MRP principles, Guardian Automotive achieved a consistent and predictable flow of materials—without overproducing or overstocking.

• Reduced obsolescence exposure, as finished-goods buffers adjust daily to true demand
• More stable production, insulated from raw-material lead-time variability
• Improved service performance, enabling more reliable and competitive market offerings
• One standardized planning process, replacing fragmented tools and rules

With the new model in place, Guardian’s planners could finally move from managing shortages to managing flow—freeing capacity to focus on continuous improvement rather than firefighting.

“Eliminating forecast dependency and buffering raw-material variability gave us a stable, standardized way to plan—without sacrificing quality or service.”
— Guardian Automotive Supply Chain Team

Future-Proof Your Supply Chain with Intuiflow

Guardian Automotive’s transformation demonstrates how Intuiflow helps complex, global manufacturers simplify planning, cut waste, and stabilize operations through real-time visibility and adaptive control.

Intuiflow connects materials planning, scheduling, and execution in one unified platform. Planners manage by priorities, not firefighting—using AI-optimized buffers and live dashboards that highlight exactly where attention is needed.

Intuiflow: One Platform. Four Core Solutions

• Materials Planning: Keep inventory aligned to real demand, avoiding shortages and overstocks.

• Scheduling & Execution: Sequence work by true priorities, not arbitrary due dates.

• Sales & Operations Planning: Link strategic goals to daily realities through shared visibility.

• Demand Planning: Adapt plans dynamically as market conditions shift.

Intuiflow is Smarter by Design

With Autopilot, Intuiflow’s AI engine continuously tunes buffers to maintain service while minimizing inventory. Embedded Power BI analytics make performance transparent, and seamless SAP integration ensures data accuracy and fast deployment.

Guardian Automotive proved that even in a high-variability, high-quality environment, it’s possible to reduce obsolescence and deliver better service with less effort.

👉 Book an Intuiflow demo here to see how it can help your organization move from forecast-driven complexity to demand-driven flow.