The Supply Chain Interview: Heiko Gerling
Resilient supply chain networks are now central to how all companies across every sector navigate disruption. Whether it's a natural disaster, geopolitical event or supply shortage, a reliable network keeps production moving and protects brand reputation.
Large consumer goods companies like Danone feel this pressure more than most. It is expanding its US footprint in a year which has arguably thrown more curveballs than 2020.
At its heart, a resilient supply chain means flexibility. It allows operations to shift with demand and market conditions – and it lets companies avoid the losses that come with overstocking or running short.
Currently, 90% of Danone’s US products are made in-country – and with each expansion, including a recent new Florida site, the company reduces dependence on external supply channels.
Behind Danone North America’s operational evolution is Chief Operations Officer Heiko Gerling.
Heiko’s global career started in Europe as an assistant to a Supply Chain Director. Since then, he’s worked across Germany, France and now the US, handling everything from procurement and logistics to profit and loss strategy.
After time in other consumer goods firms, Heiko returned to Danone in 2021 to lead operations across North America. With more than 25 years of experience, he now oversees a supply chain that includes leading brands like Activia, Oikos, Silk and Evian.
“With one of the most nutrient-dense portfolios in the industry,” Heiko explains “we are at the forefront of innovation in protein, gut health and low-sugar nutrition, leveraging deep expertise in nutrition science to shape the future of food.”
He adds: “I’m privileged to lead an outstanding team across manufacturing, logistics, customer service, procurement and sales and operations planning. Together, we’re committed to advancing the mission of bringing health through food to as many people as possible.”
Heiko’s experience across continents provides him with a wider view on how supply chains evolve, perfectly positioning him to lead Danone through its own evolution – one which includes sustainability, speed and community investment.
Embracing supply chain disruption
At Danone, supply chain resilience means having the structure, plans, agility and foresight that enable us to adapt quickly in the face of disruption," explains Heiko, "and continue to deliver high-quality, nutrition-powered products without compromise."
This resilience is a “core principle and behaviour” that runs right through Danone’s value chain – and is clear in its ongoing investments. "Year after year, we continue to emphasise resilience as a strategic priority," he adds.
Digital tools, more automation and a manufacturing footprint that’s spread out regionally all help Danone react faster when things go wrong, allowing the company to adapt quickly and keep its standards high.
"These efforts ensure we can pivot during moments of disruption while staying true to our commitment to operational excellence. Disruptions are unavoidable – and let’s face it, at times frustrating," continues Heiko. "They’re a reality in any industry, but we view them as opportunities to learn, adjust and ultimately strengthen our operations."
That learning curve isn’t new for Danone. With more than 80 years in North America, the company has had to manage plenty of challenges. Over time, it has built a supply chain with enough flexibility and foresight to deal with what’s ahead.
“For instance,” Heiko says, “during the early days of the COVID-19 pandemic, we swiftly activated alternative sourcing strategies and rerouted logistics to maintain continuity across our production sites.” He explains that experience informed Danone’s early 2025 move to identify alternative suppliers and transport routes ahead of a threatened US dockworkers’ strike.
These lessons are part of a bigger shift, which Heiko describes as “future-ready” and “antifragile,” shaped by technology investments that support long-term resilience. Whether it’s data tools, automation or advanced scenario planning, the goal is to give the company sharper insight and faster reactions.
Agility meets technology
Danone’s approach to technology in its resilient networks ensures consumer-focused efficiency by blending real-time scenario planning with a localised strategy.
Its supply chain spans a wide range of categories, from dairy to bottled water, which introduces a level of variety that requires precision planning.
“Scenario planning helps us model the impacts of potential disruptions ahead of time, so we can move quickly, minimise risk and keep our operations running smoothly,” explains Heiko.
By working closely with supply chain planning partners, Danone connects its commercial, operational and finance units to ensure everyone has the same picture.
“Danone has built localised playbooks and response protocols that are aligned with our global planning models yet tailored to the unique realities of each geography,” Heiko adds. These protocols help the company maintain consistency while reacting quickly to emerging challenges on the ground.
Among the company’s most forward-looking digital tools is its digital twin pilot. The system uses real-time data to mirror the actual supply chain, from sourcing ingredients through to delivery. This predictive model allows Danone to anticipate disruptions before they affect operations, manage maintenance in advance and keep costs under control.
“We also monitor broader indicators of impact, from how close we are staying to consumers and competitiveness, to how we are operating sustainably and efficiently,” he explains.
Even with all the technology and contingency plans, Danone’s supply chain still has people at the centre—especially when it comes to purpose.
In the US, Danone partners with FoodRecovery.org to divert excess shelf-stable products to areas dealing with food insecurity. Plus, because the partnership is year-round, the company can step in quickly - especially when disasters hit - without waiting for formal donation requests.
The initiative is part of a broader effort to align Danone’s operations with its social commitments. Whether that’s through technology, partnerships or community support, the aim is to stay agile without losing sight of the people and places the company serves.
Resilience, rooted in responsibility
The company sees resilience as central to more than just business continuity; it believes in the importance of building a system that can withstand pressure, without compromising on ethics, transparency and environmental responsibility.
This vision begins with its suppliers. Danone holds suppliers to clear standards through its Sustainable Sourcing Policy, which ensures goods it uses meet expectations right from their origins to the end product. The company backs this with monitoring and traceability, including the use of satellite technology to track deforestation, as explained in its 2023 Forest Annual Update. It’s a practical demonstration of how digital tools and high standards come together to support responsible sourcing.
For Heiko, collaboration is key to maintaining these standards. “We understand that resilience is a shared outcome,” he says, “and one that depends on proactive, transparent and data-driven collaboration between us and our suppliers and retail partners.”
Danone puts a lot into developing its long-term partnerships and ensuring trust on both sides. “We’ve created a culture where open feedback, candid communication and real-time insights form the foundation of our partner relationships,” Heiko explains.
These partnerships are key to ensuring operations run smoothly, even if one part of the network faces disruption. “We prioritise shared values,” Heiko emphasises, “especially sustainability. We ensure we work with like-minded organisations that support our mission to improve the health of people and the planet.”
As one of the largest B Corps in the world, Danone applies its environmental and social commitments across its network, strengthening resilience and community impact.
The impact of this is seen across programmes such as Re-Fuel, which aims to improve energy use and cut emissions.
The company is on track for a 46% reduction in emissions across its operations by 2030, on a 2020 baseline. Food waste has also dropped from 35 million pounds in 2020 to four million in 2024 – a dramatic improvement.
“Ultimately, our sustainability-driven supply chain is resilient and purpose-led,” Heiko adds, “serving as a lever for environmental progress white enabling us to meet market demands, navigate climate challenges and exceed stakeholder expectations.”
The network of the future
One way Danone prepares for future disruption is by combining AI, automation and workforce development to create a human-centred, resilient global supply network.
As supply chains become more complex and the risk landscape shifts, Danone is building resilience into every inch of its operations.
Heiko looks towards that future: “One of the most complex challenges we see ahead is the industry integrating AI and automation.
“We believe that human capital must be at the heart of the AI revolution,” he explains. “We’re taking a balanced approach.”
This people-first approach is also key to the company’s broader Industry 5.0 strategy. Through the new Danone Industry 5.0 Academy, the company aims to upskill 20,000 employees in automation, data-driven decision making and AI prompt engineering.
“Through initiatives like this, we’re creating a supply chain that is both technologically advanced and deeply human at its core,” says Heiko.
He encourages leaders to invest in foresight tools whilst empowering teams to adapt and improve.
My advice is to treat resilience as a value driver, not a cost center,” Heiko adds.
“In our experience,” he concludes, “resilience built in this way becomes a powerful competitive differentiator, enabling businesses to thrive, not just survive, amid disruption.”
