Kohler Builds Internal Supply Chain Design Team to Drive Speed, Agility & Ownership

In-house transformation delivers faster decisions, lower costs, and a future-ready foundation

“We’re a 150-year-old brand building a 1.5-year-old capability—and it’s already transforming how we operate.” — Mayank Kumar, Program Manager, Supply Chain Design, Kohler

Customer Snapshot

• Company: Kohler Co.

• Industry: Kitchen, Bath, Hospitality & Wellness

• Global Presence: 30,000+ associates, 6 continents, 47 manufacturing locations

• Challenge: Complex, high-mix supply chain with premium customer expectations

What challenge was Kohler facing?

After relying on third-party partners to support network modeling, Kohler realized this approach lacked the responsiveness and contextual fit needed for their complex product lines—from small bathroom accessories to luxury saunas.

• Supply chain design capability had lapsed for several years

• High product variety + customer experience demands = fulfillment complexity

• Need for more rapid, tactical decision-making at scale

• Lost knowledge from past partner-led efforts

What did Kohler do differently this time?

Kohler built a fully internal supply chain design function and selected Optilogic as its platform of choice.

• Fully cloud-based and scalable

• Fast modeling capabilities that support real-time business needs

• Enabled Kohler to build and own a detailed, dynamic digital model of their supply chain network

• Excellent support and flexibility throughout deployment

“With Optilogic, we’re asking questions and getting answers in 24 hours—not weeks.”

How was the capability built?

Step-by-step:

• Formed a diverse internal team (design, analytics, tech, business) across US & India

• Partnered closely with strategy leaders embedded in business units

• Developed a homegrown data pipeline integrated with Optilogic

• Prioritized tactical use cases to show early wins

• Built a capacity estimation tool to simulate warehouse impacts

What results has Kohler achieved?

Kohler now has an active internal supply chain design capability—and a foundation that scales.

• Fully internal capability delivering modeling at SKU and customer level

• Models inform cost-to-serve, capacity, and fulfillment strategy

• Decisions made faster, with better context and long-term retention

• Custom-fit solutions for Kohler’s business—not generic templates

“What surprised us most? The value this team delivers across the whole supply chain—not just logistics. — Maddie Seitz, Network Strategy, Kohler”

How is the capability being used today?

• Tactical Distribution Modeling: Immediate cost and service impact analysis

• Cost-to-Serve Analysis: Informs SKU rationalization and customer strategies

• Warehouse Simulation: Evaluates network flow changes before execution

• Scenario Cockpits: Business users test ideas via Excel apps and dashboards

• Monthly Planning Integration: Tied into S&OP and capital planning cycles

How does Kohler measure value?

• Cost savings vs. modeled scenarios

• Improved service metrics (faster delivery, fewer touches)

• Full truckload rates from improved assortment strategy

• Utilization of building capacity under proposed flows

• Clear KPI dashboards powered by Power BI

What’s next?

• Transportation modeling

• Sustainability and risk simulation

• Inventory optimization

• Global network optimization

• Democratize scenario modeling for real-time business use

Learn more about the Optilogic Supply Chain Design Platform

Explore how Optilogic is helping global companies like Kohler build intelligent, resilient supply chains.