Case Study
Transforming network design with digital twins: Achieving $12M savings for a leading snacks manufacturer
Solution
Opportunity
In 2024, a leading North American snacks manufacturer faced a pivotal challenge: how to accurately assign customer demand to distribution centers (DCs) and reallocate production among multiple plants in order to achieve the lowest total landed cost. The company sought a future-focused, comprehensive approach to guide distribution center space planning and utilization for 2025 through 2030.
Uber Freight’s Consulting team had previously developed separate models for production optimization and network distribution for the manufacturer. However, operating these models independently risked overlooking significant synergies and cost-saving opportunities. Recognizing the need for a holistic solution, the manufacturer engaged Uber Freight to develop an integrated network optimization model, ensuring strategic and data-driven decision-making across a complex footprint of internal plants, regional DCs, external manufacturers, and co-packers. Each co-packing facility imposed unique restrictions tied to production lines, operating hours, and product group capabilities.
Opportunity:
To address the challenge, Uber Freight deployed advanced digital twin technology, constructing a robust multi-year growth model tailored to the manufacturer’s intricate network and long-term business objectives.
Uber Freight’s Consulting team worked closely with the manufacturer to gather, cleanse, and validate vital supply chain data, ensuring a deep understanding of the production landscape, sourcing strategies, and service level requirements for all facilities. Special attention was given to the specific operational parameters of each co-packing site.
With these insights, the team developed a comprehensive model capturing both production and distribution dynamics. This enabled accurate reallocation of production and assignment of demand to optimal DCs, optimizing transportation and manufacturing flows within the company’s existing network. To ensure ongoing agility, Uber Freight created digital twin scenarios projecting demand and capacity through 2030. These sophisticated growth simulations enabled the manufacturer to precisely calculate future DC capacities and adapt operations accordingly.
Results: Significant improvements in inventory management
To learn more about how Uber Freight Consulting can optimize your supply chain network, connect with an expert today.
Connect with an expert
Results
Solution: End-to-end transportation management
Blue Bird needed a logistics partner they could trust—one that would provide both enhanced insights and opportunities to reduce costs. After frustration with their previous provider, they turned to Uber Freight for a smarter, more reliable solution.
With Uber Freight’s end-to-end Transportation Management System (TMS), Blue Bird gained the visibility they were missing across their entire supply chain. The all-in-one platform allows them to plan, execute, and manage shipments seamlessly across different modes and regions. Thanks to real-time tracking with MacroPoint, they always know exactly where their shipments are at the load level—no more guessing or hidden costs.
Sophisticated data analysis by Uber Freight’s transportation experts has enabled Blue Bird to access optimization insights that have transformed their operations. This dedicated team has helped Blue Bird centralize their procurement management, execution, business intelligence, and call-ahead standardization, driving continuous improvement and maximizing their supply chain performance.
“Before, I didn’t have access to my data and now I have access and visibility to the information I need,” Holland says. “Any reports I want to see, I’m able to get those quickly. If there’s anything I can’t find, my operations team jumps right in and gets those to me. They’re always in the weeds every day, getting our loads to execute.”
With this holistic approach, Blue Bird can ensure materials arrive on time, keeping production lines moving and avoiding delays — which can be particularly costly in the automotive sector. Uber Freight helped Blue Bird take control of their entire supply chain, including Ocean and Air freight.
Transforming network design with digital twins
Get started
Uber Freight’s integrated, forward-thinking approach yielded measurable impact:
• Identified $12.3 million in savings by optimizing transportation routes and plant allocation while sustaining service level commitments.
• Enabled accurate forecasting of long-term warehouse and DC capacity needs, supporting efficient scaling and informed capital investment.
• Delivered actionable insights to future-proof the supply chain, equipping the manufacturer to adapt rapidly to market shifts and maintain industry leadership.
By fusing production and distribution analytics into a single, dynamic optimization model, Uber Freight provided the foundation for resilient, cost-effective supply chain strategies. The manufacturer can now plan with confidence, assured that its network is optimized for both current operations and future growth.
Results: Significant improvements in inventory management
