From 10% to 75%: How SKU-Level Modeling Unlocked a Constrained Product Line

Aggregate-level forecasting is comfortable. It is also frequently wrong in the most expensive way: it hides the SKUs that are starving for capacity and the SKUs that are quietly absorbing it.

The shift from aggregate to SKU-level modeling is operational, not analytical. It requires source data discipline, a willingness to interrogate every assumption in the demand plan, and a leadership team that will act on what the model reveals.

When this product line moved from 10% to 75% capacity utilization, the win was not the model. The win was the leadership decision to act on the model the day it was finished.