Inventory and working capital released
The two largest engagements, drawn to the same scale
Consumer goods
inventory plus backorders $35M
Manufacturing
inventory across seven plants $32M
Consumer goods $15M inventory reductionPlus a $20M reduction in backorders, same year
Both numbers came down together.
Cutting stock usually means more backorders. Clearing backorders usually means more stock. This company was told to pick one. We rebuilt how the whole catalogue was forecast and reordered, and got $35M out of the two problems at once.
Forecast rebuild across the full catalogue, then the reorder rules underneath it.
Manufacturing $32M inventory reductionAcross seven plants, in six months
Seven plants stopped guessing separately.
Each site had its own view of what to hold and its own idea of what the part numbers meant, so the group carried seven safety nets for one risk. We got them onto one set of records and one way of planning.
Master data cleaned up first, then a single planning process across all seven sites.
Manufacturing On-time delivery54% to 97%
Almost every order started arriving on time.
The plant built things in whatever order the paperwork landed, losing hours a day switching the line between jobs. We changed the order the jobs run in. The tool that decides it runs against their live order book every day.
A production scheduler built in Python, handed over and still running.
Manufacturing Kitted parts lead time12 weeks to 1 week
A twelve-week wait turned into one.
A kit only ships when its last part arrives, and nobody was watching which part that was. Once the few parts holding everything up were visible and planned for, three months of waiting collapsed into a week.
Same engagement as the scheduling work above.
Manufacturing $300K reduction in systems costSoftware they no longer had to buy
We built it instead of licensing it.
They were about to sign for a product configurator. We built one that fit how they actually sell, handed over the code, and the annual licence never started. They own it outright.
Built in-house, transferred on delivery, no ongoing fee to us or anyone else.
Food & beverage $180K reduction in expiry lossProduct that stopped going out of date
Less went in the bin.
Sales and operations were planning to two different numbers, and the gap between them became product nobody sold in time. We put one monthly rhythm in place for both, plus a real process for launching something new.
Sales and operations planning, and new-product introduction, stood up from scratch.
Figures as reported by the client at the close of each engagement. We have worked with startups and with organizations over $1B, across food and beverage, consumer goods, medical devices, building products and insurance.