67% Lead Time Compression | Improved Service | Greater Supply Chain Autonomy.
Macopharma is a global leader in blood transfusion and biotherapy solutions, producing millions of transfusion kits, filters, and needles each year for healthcare providers worldwide.
Operating in a heavily regulated sector where business continuity is literally a matter of life and death, the company must ensure uninterrupted supply to hospitals and blood banks—despite global disruptions and complex, multi-site production flows.
“As the supply chain director, what is most important for me is that I am much more confident in the inventory control we are going to have. It is very easy for me to have a view on what is going on in the multiple sites and around the 24 warehouses we have around the world.”
— Alexandre Mouroz, Supply Chain Director, Macopharma
The Challenge: High Inventory, Low Service, And Lengthy Supply Chains
At the end of 2019, Macopharma faced a paradox: more than 200 days of inventory, yet service levels below 90%.
Its supply chain was long, multi-tiered, and complex—spanning three production sites (France, Poland, Tunisia), 18 subsidiaries, and 24 distribution warehouses across more than 100 countries.
Business continuity regulations required duplication of production capabilities across sites, but this redundancy also added cost, complexity, and lead time. Meanwhile, tender-based contracts lasting up to eight years demanded exceptional reliability and responsiveness.
In short, the company needed to simplify its planning, improve visibility, and boost agility—without compromising compliance or quality.
The Solution: Demand-Driven Flow Across a Multi-Site Network
Before turning to Intuiflow, Macopharma had already mapped key decoupling points where inventory could protect flow. But managing them through ERP workarounds and spreadsheets was time-consuming and inconsistent.
To regain control, Macopharma implemented Intuiflow (formerly Replenishment+) in 2020—right as the COVID-19 pandemic began. Despite lockdowns, the company’s central and site teams collaborated remotely to design and roll out the model across three plants within one year.
Why Intuiflow
- Cloud-based visibility across all sites and warehouses.
- Real-time synchronization between central and local planners.
- Autonomous site planning, aligned with global priorities.
- Demand-Driven MRP logic to filter unreliable signals and stabilize execution.
“We were not looking for another forecasting tool. We wanted to simplify flow, eliminate Excel chaos, and give autonomy back to the sites.”
— Alexandre Mouroz
The Transformation: From Fixed PMP To Continuous Flow
Previously, finished products were planned on a fixed six-week manufacturing period—a rigid system designed to secure component availability.
With Intuiflow, planners gained real-time visibility into component readiness. By ensuring availability dynamically through buffer management, Macopharma reduced its planning horizon from six weeks to two, compressing lead times by 67%.
The benefits extended beyond speed. Using Intuiflow’s relative priority alerts, every planner could see instantly which materials or subassemblies needed attention—no manual spreadsheets required.
At Macopharma’s Tunisian sub-assembly site, component shortages dropped sharply after go-live, stabilizing production and improving on-time delivery even during pandemic disruptions.
Building Resilience: From Business Continuity To Flow Continuity
Macopharma’s business continuity culture—certified under ISO 22301—had long been a corporate strength. But as Mouroz explained in the company’s global risk management webinar, the team realized that resilience isn’t just about redundancy—it’s about responsiveness.
“We were used to duplicating machines and inventories for continuity. But DDMRP pushed us to think in terms of flow: where do we really need the buffers to protect service?”
— Alexandre Mouroz
With Intuiflow’s S&OP and simulation modules, central planning now runs demand scenarios and visualizes future buffer behavior by product family.
Each site makes autonomous replenishment decisions based on live data, while the central team monitors performance, identifies risks, and drives continuous improvement.
Daily and weekly replenishment cycles are now coordinated across the network, factoring in transportation constraints and warehouse lead times to maintain global alignment.
The Results: From Crisis Response To Competitive Advantage
- 67% lead time compression (from six weeks to two)
- Improved service levels across three manufacturing sites
- Increased planner autonomy and collaboration between sites and central teams
- Higher inventory confidence and visibility across 24 global warehouses
- Resilient flow during COVID-19, with no delivery disruptions
“Despite the pandemic, we improved our performance. We maintained delivery to every customer and even strengthened our supplier communication. Intuiflow made it possible to anticipate risk instead of reacting to it.”
— Alexandre Mouroz
By embedding Intuiflow into its end-to-end planning process, Macopharma turned business continuity into a strategic advantage—earning recognition as the first European medical device manufacturer certified in resilience and continuity management.
Future-Proof Your Supply Chain With Intuiflow
Macopharma’s story shows how Intuiflow enables highly regulated manufacturers to connect resilience with flow—simplifying planning, shortening lead times, and building visibility across global networks.
Intuiflow connects materials planning, scheduling, and execution in one unified platform. Planners manage by priorities, not firefighting, with AI-optimized buffers and live dashboards showing exactly where attention is needed.
Intuiflow: One Platform. Four Core Solutions
Intuiflow Is Smarter By Design
With Autopilot, Intuiflow’s AI continuously tunes buffers to sustain service while minimizing stock. Embedded Power BI analytics make performance transparent, and seamless ERP integration ensures accuracy and speed.
👉 Book a demo of Intuiflow and discover how it can help your organization build flow-based resilience.
