Our Experience

Mission. Execution. Results.

Supply Chain Strategy & Operations

  • Distribution Network Capacity Expansion
    • Challenge: In a growing, publicly traded company, the existing distribution system needed to be consolidated and refined to capture efficiencies while increasing storage capacity.
    • Scope: Retrofit 22 DCs across the Country by adding mezzanines, conveyor systems, racking, shelving, sprinklers and lighting. Manage multiple contracts, timelines, and workstreams on parallel projects.
    • Results: Provided foundational planning, tactical leadership, and comprehensive oversight for a $33MM program retrofit that completed in 18 months within budget. 
  • Design and Implementation of Warehouse Management System
    • Challenge: An omni-channel retailer was struggling to grow e-commerce business and manage expenses with an outdated Warehouse Management System.
    • Scope: Design and implement a new Warehouse Management System application to support omni-channel operations.  Include redesign of inbound, outbound, inventory control, and customer facing data processes for parcel, ship to store e-commerce, and store replenishment orders.
    • Results: Provided leadership and business operations subject matter expertise to support the scope.  Completed the design, testing, and implementation on time and within budget.

  • Optimization through Integration of Multiple Systems
    • Challenge: A large publicly traded company had grown through acquisition and was not able to leverage synergies due to disparate supply chain systems.
    • Scope: Create a strategy and implementation plan to optimize 3 Points of Sale, 5 Warehouse Management Systems, and 2 ERP host systems across 700 stores and 25 distribution centers.
    • Results: Provided program leadership and subject matter expertise.to develop a detailed plan, including financial impact to the organization before, during, and after implementation.  Created a $62M project ($23M capital) that would create $57M in annual benefit to the organization starting in year three (<2 year payback).

Manufacturing

  • Production Line Overhaul
    • Challenge: Newly acquired privately held copper wire manufacturing concern needed major upgrades and repairs to its copper smelting and extrusion line.
    • Scope: Close the production line to cold status, then replace $2MM filtering system, construct and install a new $1MM holding furnace & refractory, and manage all contracts and subcontractors.
    • Results: Conceptualized, designed and implemented major factory outage that included comprehensive collaboration with senior leadership and the management of fifty contractors working 24/7 for ten days. $6 million in capital spend completed on time, on budget. 
  • New Equipment design-build-install
    • Challenge: Existing cylindrical furnace/refractory operating at the end of its useful life. Timing and logistics of replacing the furnace are mission-critical to the entire wire-manufacturing operation.
    • Scope: Provide oversight for the design, construction, installation, and burn-in of a new drum furnace for a copper wire manufacturing operation. 
    • Results: Organized and facilitated design meetings. Coordinated 3P refractory installation and burn-in. Furnace and all of its associated fittings and related accoutrements replaced on time, on budget, to steady state operation without disrupting the planned factory production schedule.
  • New Product Development
    • Challenge: Due primarily to historically high oil prices, electric vehicles (EV) became a burgeoning market segment. The industry demanded infrastructure and related support equipment (vehicle chargers) for viability. Fortune 100 electric device manufacturer had developed several charger prototypes and needed to streamline to production.
    • Scope: Develop new PM tools and structure to develop new prototypes into standardized, commercial products.
    • Results: Over the course of eighteen months, managed $15MM in assets and collaborated with twelve senior-level engineering professionals in the launch of four new EV charging products representing $10MM in sales. Led all manufacturing approval and testing processes including dFMEA, pFMEA, and PpAP protocols.

Capital Projects

  • Facility De-commission/Consolidation
    • Challenge: Corporate acquisition created facility redundancies that led to the need to consolidate and de-commission three large distribution center operations.
    • Scope: Create exhaustive project plans to consolidate and de-commission three supply chain facilities, the largest 425,000 ft² and the smallest 80,000 ft².  Inventory disposition plan is a critical success factor.
    • Results: Work included detailed management of hundreds of confidentiality agreements, announcement day logistics, and extensive collaboration with legal, HR, and Inventory teams.  All three facilities were successfully decommissioned and consolidated on time. 
  • Production Line Relocation
    • Challenge: Privately held engineered fabrication manufacturer has two large facilities located in South Carolina and Illinois. For strategic and financial benefit, the production line for heavy equipment operator cabins needs to be relocated to Illinois.
    • Scope: Provide inventory planning and production forecasts to seamlessly meet customer demand during the relocation activity. Work includes transfer of all manufacturing SOPs, fixturing and equipment, raw materials, work in progress, and finished goods. Work includes installing and activating new production line to steady state operation.
    • Results: Extensive risk analysis and planning led to a successful relocation with no supply interruptions. Collaborated with 25 managers while reporting directly to the EVP. Orchestrated vital meetings with suppliers and customers to remedy QA concerns.
  • New Facility Startup
    • Challenge: Reverse flow inventory at 48 DCs across the country is requiring too much floorspace and manpower to effectively manage while conducting regular distribution activities.
    • Scope: Develop and execute a plan to receive and process all reverse-flow inventory
    • Results: Led the design, site implementation, and start-up of a central reclamation and redistribution facility to support reverse-flow of owned inventory.  Start-up required $2M in capital spend to enable the operation to accommodate up to $20M in inventory. Facility employed 100  and serviced 48 DCs. 

Real Estate & Construction

  • Construction - Quick Service Restaurants
    • Challenge: Newly expanding QSR franchisees want to open new restaurants as quickly as possible to capture warm-weather revenue from ice cream sales. Existing standard construction time was 120 days from footings to soft opening.
    • Scope: Provide general contracting services to construct new quick service restaurants using fixed-fee structure. Orchestrate and manage all subcontractors. Install all kitchen equipment and complete all details to steady-state operation.
    • Results: Engineered and implemented unique construction methodologies for twelve Sonic Drive-In Restaurants ($2 million each) with a mean completion time of 52 days. Due to project efficiencies, franchisee NOI increased 19% in the first year of restaurant operation.
  • Real Estate – Residential Development
    • Challenge: Private equity group acquired 52 vacant lots in a tightly controlled residential development with an objective of completing and selling 52 homes in a two-year period. These interspersed vacant lots were the last in a development with over one hundred pre-existing homes and a very engaged homeowners association. 
    • Scope: Provide market analysis, financial modeling, and a detailed project plan to construct 52 modular homes over a two-year period. Work includes structural and interior design, collaboration with community leaders, and listing broker interview and selection.
    • Result: Within 90 days, the project plan had been completed and the investors were off to a running start. Work included onsite visits to five manufacturing facilities; interviewing service providers who could execute the plan; and project analysis and reporting to investors. 
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