Managing complexity and uncertainty, the never-ending supply chain challenge

Across a wide range of sectors, organisations must navigate increasingly complex and interconnected global supply chains. These global challenges are often unpredictable, yet they can profoundly influence an organisation’s performance and long-term success. Managing complexity and responding to unforeseen disruptions requires agility and foresight without which, the entire organisation may be exposed to amplified risks and have its supply chain resilience called into question.

The recent OECD Supply Chain Resilience Review 2025 underscores this point, noting that significant import concentration has increased by 50% globally since the late 1990s, making supply chains more vulnerable to external shocks. Moreover, efforts to re-localise supply chains could reduce global trade by over 18% and cut global real GDP by more than 5%, highlighting the need for smarter, not smaller, supply chains.

Crucially, the report emphasises that resilience is not about eliminating risk, but managing it. The most effective supply chains are those that are agile—able to respond quickly; adaptable—able to evolve over time; and aligned with shared interests among firms, governments, and stakeholders. These qualities are essential for navigating disruptions without retreating from global trade.

What is a digital twin (And why should you care?)?

A digital twin is a virtual mock-up, or digital representation of your supply chain operations. This could come in a variety of different forms, from forecasting a small element of your local supply chain, through to a completely scaled up system that maps your entire global operation.

So how does this help you? As a snapshot, a digital twin allows you to do the following:

  1. Increased Supply Chain visibility and transparency – Enhanced visibility allows organisations to monitor every stage of their supply chain in real time, from raw material sourcing to final product delivery. With advanced analytics and dashboards, stakeholders can quickly identify bottlenecks, track inventory levels, monitor supplier performance, and respond proactively to disruptions (US tariffs?).This transparency builds trust across the value chain and supports compliance with regulatory and sustainability standards.
  2. Improved Decision making – With access to comprehensive data and simulation tools, organisations can model various supply chain scenarios such as demand surges, supplier failures, or geopolitical disruptions. These simulations enable data-driven decision-making, allowing supply chain leaders to evaluate the impact of different strategies before implementation. This reduces risk, enhances agility, and supports more resilient planning.
  3. Cost savings opportunities– The integration of real-time data and analytics makes it easier to pinpoint inefficiencies such as excess inventory, underutilised assets, or costly logistics routes. By identifying these areas, organisations can implement targeted improvements like route optimisation, supplier consolidation, or automation leading to significant cost reductions.

Mars, a global organisation known for confectionery, pet care, and food provides an impressive case study, through the implementation of a digital twin. Mars have seen truck utilisation move from a mid-80% utilisation rate through to an impressive 95%. This has a huge impact on the number of road miles covered by Mars, making not only savings on transportation costs, but supporting Mars in working towards their overall sustainability targets. The initiative demonstrates how data-driven innovation can deliver both operational efficiency and environmental impact at scale.

Time to Twin Up?

Getting started in the Digital Twin space can feel like a big and sometimes intimidating step, especially at the beginning. The great thing about digital twins is that they can be completely tailored to your specific need, and scale to meet your required needs.

At 4C Associates, we have the expertise to help you start small, scale smart, and deliver measurable results. Our team has a proven track record of unlocking tactical, incremental gains in cost, output, and service through improved inventory strategies, de-bottlenecking manufacturing and warehouse capacity, and optimising logistics routes and 3PL services. Whether you’re just beginning or looking to expand your capabilities, we’re well positioned to guide you on your Digital Twin journey. To maximise impact, we offer Digital Twin as a service and can support you in building internal capability within your team, ensuring long-term value and self-sufficiency.

Reach out to Erika Biggadike to learn how we help you maximise impact.