For many manufacturers, seasonality creates significant operational challenges. Demand surges during peak periods can strain production capacity, increase lead times, and negatively impact customer service. During slower periods, companies often find themselves reducing production and laying off employees, only to face hiring and training challenges when demand returns. This was the situation facing Mission Rubber.

As a leading manufacturer serving the building products market, the company experienced significant seasonal fluctuations in demand. Customer service suffered during peak periods, lead times increased, and workforce stability became a recurring challenge. Leadership knew there had to be a better way. To improve service levels, better align capacity with demand, and create a more stable operation, Mission Rubber partnered with LMA Consulting Group.

The results were significant. Through improved SIOP (Sales Inventory Operations Planning) processes, capacity planning, inventory strategies, and ERP utilization, Mission Rubber reduced workforce turnover costs by more than $200,000, improved customer service performance, and cut the duration of service disruptions during major demand surges by approximately 50%. The company created a more stable workforce, improved operational performance, and built a more predictable foundation for growth.

The Challenge: Seasonal Demand Was Impacting Service

Mission Rubber’s busiest season occurred during the summer months when customer demand increased significantly. While the company successfully managed production during much of the year, peak season created challenges. Customer service levels declined. Lead times increased. Customers became frustrated. At the same time, the business experienced the opposite challenge during slower periods. Demand declined, production requirements decreased, and workforce reductions often followed. The result was a cycle that impacted customers, employees, and operational performance. Leadership wanted to improve service while creating a more sustainable operating model.

Starting with a Supply Chain Assessment

LMA began with a comprehensive assessment of the company’s supply chain, planning processes, operational capabilities, and system utilization.

The assessment focused on:

  • Demand patterns and seasonality
  • Historical sales performance
  • Inventory strategies
  • Capacity planning
  • ERP utilization
  • Production planning processes
  • Customer service performance
  • Flow of work to the shop floor

The objective was to understand the root causes of service issues and identify opportunities to better align demand, inventory, capacity, and operations.

Implementing SIOP and Capacity Planning

One of the key findings was the need for a more structured planning process. LMA helped Mission Rubber implement and strengthen its SIOP process to provide greater visibility into future demand and operational requirements.

The company began evaluating:

  • Historical sales trends
  • Seasonal demand patterns
  • Future customer requirements
  • Capacity constraints
  • Inventory requirements
  • Production plans

This improved visibility allowed leadership to make more proactive decisions and better prepare for peak demand periods. Rather than reacting to seasonal spikes, the company could plan for them months in advance.

Building Inventory Strategically

A critical component of the solution involved changing how inventory was managed. Historically, inventory levels did not fully support the significant increase in demand during peak season. Through the SIOP process, Mission Rubber developed inventory strategies that allowed production to build inventory during slower periods when capacity was available.

This approach created several benefits:

  • Better service levels during peak season
  • Improved lead-time performance
  • Reduced production disruptions
  • Better utilization of manufacturing resources
  • Improved customer satisfaction

Most importantly, the company was prepared when customer demand increased. Strategic inventory positioning became a key factor in reducing the impact of seasonal demand spikes and helping the organization recover service levels significantly faster than in the past.

Leveraging ERP and Planning Tools More Effectively

LMA also worked with the company to improve the utilization of its ERP system and planning tools. The focus was not on replacing technology but on getting more value from existing systems. By improving planning processes, reporting, and visibility into inventory and capacity requirements, leadership gained better information for decision-making. The result was a stronger connection between demand planning, inventory planning, and operational execution.

Stabilizing the Workforce

One of the most significant outcomes extended beyond customer service. Historically, slower periods often resulted in workforce reductions because production requirements declined. With better planning and inventory strategies, the company was able to maintain more consistent production throughout the year through level-loaded production schedules. Rather than reducing staffing levels during slower months, employees remained productive building inventory that would support future customer demand.

This created:

  • Greater workforce stability
  • Improved employee retention
  • Increased productivity
  • Better operational continuity
  • Reduced hiring and training costs

By reducing the cycle of layoffs, rehiring, onboarding, and retraining, Mission Rubber achieved workforce-related savings of more than $200,000 while retaining experienced employees and preserving valuable institutional knowledge. The company created a more stable work environment while avoiding the disruption and expense associated with rebuilding the workforce each season.

Improving Service During Large Order Surges

Another important benefit emerged when the company experienced large customer orders and seasonal demand spikes. No manufacturer can completely eliminate the operational impact of major demand increases. However, the SIOP process dramatically reduced the duration and severity of service disruptions. With better visibility, inventory positioning, and capacity planning, service levels recovered more quickly and operations remained far more stable than in the past. When significant sales spikes occurred, Mission Rubber reduced the duration of service-level challenges by approximately 50%, allowing the company to respond faster to customer demand and return to target service levels much more quickly than previously possible. The organization became significantly more resilient, responsive, and prepared to manage demand volatility.

The Results

Through its partnership with LMA Consulting Group, Mission Rubber achieved meaningful business improvements:

  • Improved customer service and lead-time performance
  • Reduced the duration of service-level disruptions during demand spikes by approximately 50%
  • Enhanced SIOP and capacity planning capabilities
  • Better utilization of ERP systems and planning tools
  • Improved inventory positioning and readiness for seasonal demand
  • Reduced impact of large order surges
  • Faster recovery of service levels during peak demand periods
  • Increased operational stability
  • Improved workforce retention and employee stability
  • Reduced workforce turnover costs by more than $200,000
  • Greater visibility into future demand and capacity requirements
  • Stronger overall operational performance

Most importantly, the company created a more predictable and scalable operation capable of supporting customers while maintaining workforce stability.

Turning Seasonality into a Competitive Advantage

Many manufacturers view seasonality as a problem that must be managed. The most successful organizations turn it into a strategic advantage. By improving visibility, implementing SIOP, strengthening capacity planning, and leveraging ERP systems more effectively, Mission Rubber transformed the way it plans and executes operations. The company reduced workforce turnover costs by more than $200,000, improved customer service, and cut the duration of service disruptions during major demand surges by approximately 50%. Just as importantly, it created a more predictable and scalable operation capable of supporting customers while maintaining workforce stability. The result was happier customers, a more stable workforce, stronger operational performance, and a supply chain better equipped to support long-term growth.

 

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Published: March 10, 2018 | Updated: May 19, 2026