The Role of Control Towers in End-To-End Supply Chain Optimization

Supply chains have been at a breaking point for a while now. Supply chain visibility and
resilience played a crucial role in helping companies manage disruptions and balancing
supply with demand. This paved the way for supply chain control towers that provided
end-to-end visibility and transparency within global networks.

While supply chain visibility is a crucial first step, many companies stop there, unsure how
to fully leverage its potential. Simply having end-to-end visibility isn’t enough to drive
significant value.

The supply chain industry is at a breaking point. More than 70% of leaders need more than 2-3
system to make basic decisions, and 58% of billion-dollar companies struggle with critical
blind spots.

New research from 200+ supply chain executives reveals:

• Only 22% of control towers drive meaningful action
• Where critical visibility gaps exist
• How leaders are addressing system fragmentation.

So, what makes a supply chain control tower truly worth the investment?

The true power of a control tower comes from its ability to help companies act based on the
insights it provides. By integrating AI and machine learning, control towers can
automatically raise alerts and recommend response actions. This allows businesses to move
beyond reactive decision-making and towards orchestrated, automated solutions—streamlining
operations, reducing manual tasks, and optimizing complex workflows for greater efficiency.

A supply chain control tower makes supply chain networks more customer-centric, sustainable,
responsive, and agile. This is made possible by bringing together processes, technology
infrastructure, data, and teams to drive enterprise value.

An end-to-end control tower must be built on four continuously evolving pillars:

• Use Case-Oriented Features
• Agile Supply Chain Frameworks
• Flexible Technological Infrastructure
• Robust Data Strategy and Governance

Use Case-Oriented Features

To derive the full value of a supply chain control tower, companies should identify specific
use cases that will translate into business value. Such requirements will be facilitated by
control tower capabilities like visibility, predictive alerts, scenario modeling, and
automated operational execution which, combined, allow the control tower to predict and
respond quickly while optimizing the execution of the supply network.

A Real-World Example of Warehouse Optimization through Supply Chain Control Towers

One example of how a supply chain control tower can drive significant business value comes
from a leading technology company in the semiconductor industry. This company operates a
highly specialized warehouse that serves as a critical hub for managing a vast range of
components, from tiny screws to large steel frames. The warehouse is designed to support the
assembly of customized machines in adjacent cleanrooms, where each machine has a unique set
of requirements and materials.

The warehouse houses between 30,000 and 60,000 stock-keeping units (SKUs), with inventory
fluctuating daily based on the machines being assembled. To optimize operations, the
warehouse is divided into five distinct storage areas. These systems work together to
quickly retrieve materials from across the warehouse whenever a cleanroom places an order.

These materials are then transported to a dedicated Material Intake & Contamination Control
department, where they undergo a rigorous inspection, unpacking, and cleaning process in a
UV-lit darkroom. The goal is to ensure that these materials are ready to be delivered to the
cleanroom as a complete set—often within 30 minutes.

A control tower simplifies this scenario by providing real-time tracking of inventory across
all storage areas, allowing for faster retrieval and reducing human errors. Additionally, it
automates key tasks, such as the inspection and cleaning process, and coordinates seamlessly
between different systems, ensuring that the right materials are delivered to the right
place at the right time.

By integrating these technologies, the company can anticipate demand, optimize workflows, and
deliver customized solutions with agility—demonstrating the real-world impact of control
towers in enhancing supply chain efficiency and responsiveness.

Agile Supply Chain Frameworks

One key learning point for business across all industries is that supply chains need to be
much more resilient. However, the solution does not lie in simply building redundant
capacity or inventory. A cost-effective way out requires creating a more resilient supply
chain with ‘intelligent visibility’.

Intelligent visibility provides the combined advantage of structural and dynamic visibility,
supported by cutting-edge analytical techniques and artificial intelligence.

With structural visibility, companies can gain an overview of their operations either at a
specific moment or over a defined period. This insight allows them to identify hidden
challenges and gain a deeper understanding of factors such as:

• The locations of their suppliers
• The sites of their manufacturing operations
• The logistics routes they and their partners utilize
• The interconnectedness across the entire supply chain network
• Potential vulnerabilities and risks within the supply chain

On the other hand, dynamic visibility enables companies to track and react to events as they
unfold. It represents a more advanced level of capability, offering insights into:

• The current location of products throughout the supply chain
• The performance of plants and warehouses
• The timing and location of disruptions
• The impact of disruptions and their specific effects

Advanced supply chain control towers like the Optima Control Tower provide a deeper view into
multi-tier supply chain networks. AI-powered insights help businesses respond faster and
make data-driven decisions to manage supply chain disruptions.

Both types of visibility are crucial, but when combined, they allow companies to identify
their most vulnerable areas in the face of disruptions and prepare strategies to recover
swiftly. Intelligent visibility further enhances this by enabling agile workflows, allowing
companies to adapt more effectively and strengthen their resilience against various
disruptions.

A control tower can transform the existing supply chain operations and will drive changes to
existing organizational processes to run it. By driving greater collaboration, an SCCT also
requires new customer-centric performance metrics and processes that can help create better
benefits for the entire network.

Flexible Technological Infrastructure

A supply chain control tower is designed on flexible, cloud-based system architectures, which
are essential for its ability to scale and integrate with additional entities and functional
use cases as business requirements evolve and market technology advances.

By implementing the control tower through agile sprints focused on specific use cases,
companies can expand to new entities, regions, or functional areas, while simultaneously
enhancing its capabilities in areas like visibility, alerts, and response management.

Robust Data Strategy and Governance

A critical element of a supply chain control tower is its robust data strategy and governance
framework. To ensure data is accurate, timely, and actionable, companies must establish
clear data governance protocols. These include defining data ownership, establishing data
quality standards, and setting up real-time data feeds across the supply chain network. This
approach ensures that data from various sources—whether it be suppliers, warehouses, or
logistics partners—remains consistent and reliable.

Governance also ensures data security and compliance with regulations, particularly when
managing sensitive information such as customer orders or supplier contracts. With
well-established governance practices, a supply chain control tower can offer transparency
and trust, allowing companies to make informed decisions. In turn, this supports the
seamless integration of data-driven insights into day-to-day operations, enabling faster,
more accurate responses to supply chain disruptions.