For manufacturers in the consumer goods industry, agility is no longer a luxury—it’s a lifeline. In today’s environment, disruptions have become the rule rather than the exception. From raw material shortages and shifting consumer demands to labor constraints and volatile markets, the pressure to adapt—and fast—is unrelenting.
Yet many companies still rely on spreadsheets and static planning tools that simply can’t keep up. In fact, roughly 80% of consumer goods manufacturers continue to use traditional planning methods like Gantt charts, even as supply chains become more complex and product portfolios more dynamic. This mismatch between old tools and new challenges often results in excess inventory, production delays, and missed opportunities. To bridge this gap, manufacturers are beginning to adopt advanced planning and scheduling (APS) systems that offer real-time adaptability, scenario modeling, and capacity-based scheduling. At the heart of this transformation is a concept known as “production agility”—a strategic shift toward more responsive, data-driven planning.
From Reactive to Responsive: The Shift Toward Production Agility
Production agility centers on one key idea: dynamic planning based on real-time data. Instead of relying on rigid production plans that may quickly become outdated, agile systems adjust to new constraints on the fly. Whether a machine goes offline, a shipment is delayed, or consumer demand shifts overnight, agile planning helps manufacturers adapt with minimal disruption.
A cornerstone of this approach is the use of a “virtual twin”—a digital model of the production environment that captures not just the layout and resources of the factory, but also the rules, relationships, and constraints that govern its operation. This model allows planners to simulate different production scenarios, evaluate outcomes, and optimize schedules—all before any real-world changes are made.
Addressing the Big Challenges
Several persistent challenges in consumer goods manufacturing can be mitigated through agile planning:
- Excess Inventory: Agile systems support just-in-time (JIT) inventory practices by synchronizing procurement with actual production needs, reducing waste and lowering storage costs.
- Shelf-Life Management: For perishable goods, production timing is everything. Dynamic scheduling ensures that products are manufactured and distributed with enough runway to maximize freshness and shelf life.
- Resource Utilization: Downtime, inefficient setups, and bottlenecks are costly. Agile planning helps group compatible product runs, reduce changeovers, and allocate tasks to optimize output without overloading any single resource.
- Customization and Variability: With the growing demand for personalized products, manufacturers must flexibly switch between product variants. Agile systems make it easier to shift between configurations while maintaining efficient throughput.
Measurable Results Without Reinventing the Wheel
One of the common misconceptions about advanced planning tools is that they require massive overhauls of existing systems. In reality, many modern APS solutions are designed to integrate with a manufacturer’s current enterprise systems—ERP, MES, and beyond. The goal isn’t to replace everything, but to enhance visibility, streamline workflows, and automate decision-making where possible.
Real-world results suggest the value is worth the investment. In many cases, companies that adopt agile planning methods report a return on investment within 12 months. Benefits include:
- Up to 70% improvement in planning agility
- Reduced planning time by 30–50%
- Improved service levels, with on-time deliveries reaching 90–100%
- Lower inventory and WIP levels, enhancing cash flow and space utilization
- Faster lead times and increased responsiveness to market shifts
These gains don’t just impact short-term efficiency—they set the foundation for long-term competitiveness. With better control over production flows and deeper insight into operational data, manufacturers are positioned to innovate more confidently and serve their customers more effectively.
Making the Case for Change
For many organizations, the journey to production agility starts with recognizing the limits of legacy tools. Static planning may have worked in a simpler time, but today’s realities demand a more flexible, integrated approach. Moving from reactive fire-fighting to proactive planning doesn’t just improve performance—it builds resilience in the face of uncertainty.
Whether you’re producing high-volume goods on a build-to-stock model or handling complex custom orders on demand, agile planning offers a pathway to better results with less friction. The technology is ready. The need is clear. The next move is up to you.
Check out the new Dassault Systèmes ebook: From Static to Dynamic, Fast: The Planning Solution for Production Agility
Brian Carboni is the Global Marketing Director for the CPG-Retail Industry at Dassault Systèmes.