Case Study Resilient & sustainable design of the entire supply chain
The bilstein group relies on PSIglobal to optimize its supply chain network.
Ferdinand Bilstein combines the well-known product brands febi, SWAG and Blue Print under the bilstein group umbrella. Together, the bilstein group offers more than 75,000 different technical replacement parts for professional vehicle repairs. The internationally-operating group of companies supplies its products to over 170 countries.
- Industry: Supplier and manufacturer of spare parts for cars and commercial vehicles
- Employees: 2,700 employees worldwide
- Turnover: €1.12 bn total turnover (2024)
- Deployed software: PSIglobal
- Type of project: Brownfield
Challenges
The bilstein group faced a number of logistical challenges that required a reassessment and optimization of its supply chain network. One key challenge was to create a comprehensive representation of both external transportation routes and internal logistics processes. In particular, the software solution needed to incorporate existing, complex inbound and outbound storage rules, which were difficult to modify, as well as the associated internal processes within the individual warehouse areas.
Another key question was whether the existing warehouse capacities could accommodate a revised routing structure between the regional warehouse in France and the central warehouses in Germany. At the same time, it was difficult to fully assess the impact of potential changes on the supply chain network as a whole.
Objectives
The goal was to create a comprehensive and transparent digital representation of the entire supply chain using a suitable software solution. This would make existing transportation and logistics processes, as well as their interdependencies, transparent and easier to analyze.
Based on this foundation, the bilstein group aimed to establish a sound basis for evaluating potential future changes to its supply chain network and identifying their impact on transportation routes, warehouse operations, and capacity at an early stage. In particular, the objective was to determine whether alternative routing scenarios between the regional warehouse in France and the central warehouses in Germany could be implemented within the available capacities.
Solution approach
Solution components
- Data management
- Logistics network routing
- Allocation optimization
By using PSIglobal, the bilstein group has a digital twin of its supply chain that enables precise modeling of both internal and external logistics operations. The software’s capabilities have already been demonstrated in two pilot projects, focusing on production optimization and logistics network routing, respectively.
Through targeted configurations in PSIglobal, the bilstein group can now incorporate complex cost models based on a wide range of influencing factors. This enables continuous analysis and flexible adjustment of existing rules, providing the foundation for ongoing optimization across the entire supply chain.
For example, the French pilot project resulted in the development of a successful standard model that was subsequently transferred to other regions. In addition to optimizing Total Cost of Ownership (TCO), PSIglobal improves capacity planning and warehouse utilization through accurate forecasts for inventory management between regional and central warehouses.
The result
With the digital twin, we are laying the foundation for a resilient and sustainable design of the entire supply chain. Thanks to the scenario planning in PSIglobal, we ensure that we can continue to offer our customers the best possible service in the future.
By implementing PSIglobal and developing a digital twin of its supply chain, the bilstein group has established a strong foundation for continuous process improvements. Data-driven scenario planning enables reliable forecasts for capacity and inventory management and ensures a scalable standard model that can be flexibly applied to international locations. This allows the company to optimize costs in the long term and continue to offer its customers high levels of service in the future.
