Assessment and Management Consulting Firm with a Strong Focus on Technology

Assessment and Management Consulting Firm with a Strong Focus on TechnologyAssessment and Management Consulting Firm with a Strong Focus on TechnologyAssessment and Management Consulting Firm with a Strong Focus on Technology

Increasing the Bottom Line

Overview

Title: General Manager
Area of Specialization: Operations
Location: Ohio
Term: 24 Months

Background

A manufacturing plant in Ohio experiencing unplanned growth is struggling to adapt to the changes. This struggle has led to negative impacts on the bottom line month-over-month. This organization is looking for someone to help control the growth, formalize systems, standardize processes, remove personnel dependencies, and train middle management.

Project Plan

  1. Evaluate Staff Strengths and Weaknesses
  2. Evaluate Financials
  3. Evaluate Vendors
  4. Implement Manufacturing Systems
  5. Expanded Implementation of ERP
  6. Full Inventory Cycle Count
  7. Cross Train Staff
  8. Realign Staff
  9. Add 3rd Shift
  10. Standardize Packaging Options
  11. Standardize Production Runs Based on Required Packaging
  12. Standardize Vendors
  13. Standardize Raw Materials
  14. Eliminate Formula Variances
  15. Full Cost Analysis of All Manufactured Items
  16. Evaluate Customers
  17. Outsource Items that are Inefficiently Produced
  18. Adjust Customer Pricing
  19. Implement Just-in-Time Raw Material and Packaging Initiatives
  20. Implement Short Shipment Windows to Eliminate Finished Goods Storage
  21. Implement 3PL Initiative for Customer Owned Inventory
  22. Standardize Forecasting Methodology
  23. Implement Supply Chain Management Solution
  24. Source a Full Time General Manager

Length of Engagement

The engagement was originally scheduled to last for 12 months. Due to the nature of the work and continual overturn in potential General Manager candidates, the engagement lasted approximately 24 months.

Outcome

With an expanded engagement window, we were able to ultimately accomplish more tasks. At the beginning of the project, the manufacturing plant was losing approximately $750,000 per month. At the end of the engagement, the plant was making a profit. Being a family owned business, the General Manager who took over the plant was an extended family member who was pivotal in completing all the tasks needed to turn the operation successful.