When Your Business Gets Harder to Run Than It Should

Client Impact Results

Planning Transformation: Replaced reactive production planning with sophisticated SIOP process

Reporting Efficiency: Reduced production reporting time from 3-5 days to real-time, automated information.

Financial Close: Decreased month-end closing from more than three weeks to less than one day

Process Integration: Fully automated production and inventory reporting through integration with financial accounting

Operational Proactivity: Enabled management to proactively plan, schedule, and execute in a continuous improvement cycle

Regulatory Compliance: Enhanced tracking capabilities for cGMP and CFR Title 12 compliance.

Client Impact Results

• Planning Efficiency: Reduced daily mill planning from over 3 hours to under 30 minutes

• Automation: Moved operations from nearly 100% manual to approximately 90% automated

• Scheduling Accuracy: Achieved ~98% on-the-hour accuracy for customer bulk pickups

• Inventory Management: Improved retail inventory accuracy from under 50% to approximately 100%

• Cost Reduction: Eliminated a multimillion-dollar pallet reuse operation

• Price Management: Implemented daily repricing on commodity fluctuations

• Cultural Transformation: Delivered lasting change inside a 100-year-old organization with embedded resistance

Client Impact Results

• Cost Reduction: Reduced railcar demurrage and tanker truck partial-load returns by over 95%

• Order Fulfillment: Achieved real-time Available-to-Promise commitments during order taking

• Supply Chain Visibility: Established first-time visibility of trans-Atlantic port-of-entry ownership and tracking

• Financial Efficiency: Reduced month-end financial close from more than two weeks to less than two hours

• Process Automation: Implemented Lean Order-to-Cash, Procure-to-Pay, rate-based scheduling, and automated supplier scheduling

• Customer Satisfaction: Significantly reduced product shortages and delivery delays

Client Impact Results

• Cost Savings: Identified approximately $20 million in savings from unprofitable products and processes across specific distribution centers

• Customer Retention: Reversed the in-flight termination of a major channel partner — the data proved they ranked in the top third of profitability

• Decision Making: Replaced allocation-based assumptions with empirical, activity-level profitability evidence

• Resource Allocation: Redirected resources toward the most profitable channels and customers

• Operational Efficiency: Isolated the specific cost drivers for targeted improvement

Results

Sales Optimization: Identified opportunities to restructure sales commission models to drive profitable growth

Product Profitability: Pinpointed unprofitable customer/product combinations for remediation

Operational Efficiency: Discovered and addressed Production and Quality Lab inefficiencies

Strategic Focus: Enabled client to take immediate steps to improve product profitability

Cost Reduction: Identified and implemented specific operational cost reduction initiatives

Data-Driven Decisions: Provided management with actionable business intelligence for strategic planning

Client Impact Results

• Financial Transformation: Improved EBITDA 30% in less than two years

• Quality Revolution: Reduced shop floor mistakes and rework by over 75% within the first year

• Work-Life Balance: Shop personnel took holidays during busy season for the first time in 20 years

• Manufacturing Excellence: Reduced manufacturing cycle times from 8+ months to under 3 months.

• Supply Chain Optimization: Reduced global sourcing of forged steel components from 18+ months to under 4 months, enabling millions in additional customer jobs

• Operational Efficiency: 

      Reduced job estimating from weeks to less than 4 hours with increased accuracy

      Decreased project status reporting lead-time from 1+ week (with <50% accuracy) to under 1 day (with >98% accuracy)

      Eliminated time-consuming daily planning meetings attended by all Directors, Managers, and Supervisors

Client Impact Results

• Cost Efficiency: Reduced product development costs by approximately 74% through design changes and in-house capability

• Time-to-Market: Launched MVP Version 1 in under 3 months

• Organizational Development: Stood up functioning IT and Data Science departments in under 4 months, completing the exit from the third-party development firm

• Revenue Growth: Contributed to a 10% increase in sales revenue through strategic recommendations

• Leadership Continuity: Onboarded the new CEO while preserving operational momentum

Development Velocity: Enabled team to promote vetted code to QA within 2 months. Stakeholder Confidence: Established continuous code promotions to Customer Acceptance within 3 months. Leadership Continuity: Successfully recruited and onboarded permanent IT Director within 6 months. Project Recovery: Put the stalled $250M implementation back on track toward successful completion.

Client Impact Results

• Cost Efficiency: Identified approximately 10% in operational expense reductions

• Rapid Implementation: Established functional Agile/Scrum DevOps team within 1 month

• Operational Excellence: Delivered streamlined operations and on-demand reporting systems within 2 months

• Team Autonomy: Achieved self-sufficient operations of the development team within 3 months

• Digital Transformation: Completed transition from manual, paper-based documents to electronic document management within 4 months

Client Impact Results

Strategic Clarity: Demonstrated increased profitability of fund-of-funds model within 1 month

• Project Recovery: Terminated underperforming third-party consulting firm within 6 months and redirected implementation

• System Modernization: Successfully implemented LedgeX Portfolio Management Software in under 1.5 years

• Product Enablement: Enabled new Fund-of-Fund product offerings aligned to institutional mandates

• Enhanced Client Engagement: 100% Automation of Client Reporting enabling Monthly vs Quarterly

• Operational Efficiency: Reporting 99%+ improvement

• Data Excellence: Achieved approximately 98+% improvement in data quality and accuracy

• Knowledge Transfer: Successfully implemented Agile DevOps and prepared internal staff for long-term system maintenance.

Client Impact Results

• Crisis Management: Documented 54 SQL Server databases and thousands of VBScript programs within 2 weeks; completed operational triage within 3 weeks; disaster recovery protocols live within 1 month

• Organizational Development: Stood up a functioning IT organization with an operating Agile DevOps team

• Business Intelligence: Delivered insight into rental trends, product profitability, and consumer preferences by region

• Strategic Vision: Provided franchisees data-driven competitive intelligence through an integrated SaaS application

Client Impact Results

• Cycle Times: Reduced from 8+ months to under 3 months

• Profitability: Unprofitable plant became a positive contributor

• Transferability: Operating model validated across a second manufacturing context in 6 months

• Outcome: Plant subsequently acquired by GE

Client Impact Results

• Competitive Win: Within 2 weeks of CPQ launch, the client won a multi-million-dollar contract by turning a complex quote in under 2 hours — competitors quoted ~3 weeks

Client Impact Results

• Human Outcome: For the first time in 20+ years, shop personnel took Thanksgiving and Christmas vacations during the busy season — planning discipline made the capacity visible

Client Impact Results

• Savings: $2.8M identified — 18.9% OpEx reduction

• Value Classification: 59% of process work was NVA or NVA-Essential

• Shadow Systems: 43% of overall cost consumed by non-sanctioned systems

• Workforce: 9% optimization validated as achievable without operational impact

• Lab Procedure: Main daily procedure reducible from 45 minutes to 5

Client Impact Results

• Manual Tasks: Reduced from 30 to fewer than 5

• Work Order Accuracy: Above 95%

• Shipping Accuracy: Above 95%

• Integration: Corporate ERP integration fully automated, eliminating double-entry

Client Impact Results

• On-Time Delivery: Improved above 95%

• Cost: Significant service-cost reduction; inventory shortages resolved

• Finance: Progress billing and retainage tracking fully automated

• Scale: Operating model replicated 1 site to 3 in 6 months, on budget

Client Impact Results

• Immediate Savings: ~$2M annualized

• Long-Term: ~$100M savings potential

• Approval: Future-state approved for global rollout across the merged entity

• IP Milestone: The BAS™ methodology was formally named during this engagement

Client Impact Results

• Unified Framework: One process architecture governing global operations

• Regional Clarity: GDPR, post-Brexit, and delivery-center governance made explicit

• Standardization: Service levels consistent across all five entities

Client Impact Results

• Total OpEx Modeled: $4.6M

• Value-Added Share: Only 21.2% of operating cost was directly value-creating

• Addressable Savings: $1.287M annually across 5 initiatives — automated reconciliation, credit card processing, A/R collections, self-service portal, credit screening

• Shadow IT: $793K (27.6%) consumed by non-blueprint systems

Client Impact Results

• Stabilization: Global engine SCM stabilized in under 2 months

• Sourcing: Long-term sole-sourcing to OEMs secured in under 6 months via European supplier agreements and formal SIOP

• NVA: Over $700K identified in 2 weeks (over $1M total annualized savings)

• Pricing: Customer confusion and OTC pricing issues from annual model changes eliminated

Client Impact Results

• Automation: Converted manual, error-prone procurement planning and purchasing to automated, exception-based management

• Visibility: Management analysis and exception reporting delivering the daily business pulse

• Scalability: Customer-specific and non-stock items managed without administrative burden

Client Impact Results

• Fee Avoidance: 19 months of projected consulting fees eliminated, plus two JDE subscriptions and two data centers of OpEx

• Payroll: Monthly multi-day re-keying reduced to under 5 minutes

• Procurement: 7 processes digitalized; 90 users trained; real-time requisition and approval

Client Impact Results

• Throughput: ~1,800 daily active work orders running on automated planning

• Recovery: A three-time failed implementation delivered in 9 months

Client Impact Results

• Sales Orders: Real-time completion vs. 2–8 hours, via 15 Advanced Pricing configurations replacing 1M+ manual pricing structures across government, group-buying, and B2B channels

• Delivery: Program completed in 11 months total despite the mid-program transition

Client Impact Results

• Cycle Times: Production cycle times reduced by 60%

• Accuracy: Planning and scheduling accuracy increased above 99%

• Modernization: Excel/Access/Word workarounds replaced by lean OTC and manufacturing processes

Client Impact Results

• Throughput: Increased over 90%

• Raw Material Accuracy: Above 98%

• Delivery: Quality and missed-delivery crisis resolved in 6 months

Client Impact Results

• Go-Live: MS Dynamics GP live in under 2 months

• Risk: Federal fines and suspension averted

Client Impact Results

• Data Issues: Over 97% eliminated, resolving major material shortages

• Customers: Chargebacks and product-delay crisis with primary customers resolved

• Timeline: Stabilization in 1 month; production SaaS in under 5

Client Impact Results

• Cost Structures: Accurately tracked and managed for the first time in 30+ years

• Production: Output matched to demand, ending out-of-control quantities and cost

Client Impact Results

• Feasibility: Demonstrated a workable systems model for complex multi-country outsourced production — on time, on budget

Client Impact Results

• Result: Null hypothesis rejected — 5 core profiles generated by ML now anchor the proposed CPQ application

• Adoption: Future-state QTC and PLM approved by C-level and departmental leadership

Client Impact Results

• Conversion Speed: Under 2 weeks vs. 3 FTE-years estimated; launch on time and on budget

• Integration: Inter-company process costs reduced ~85%; 100% bulk raw material availability

• Cost Recovery: Over $5M identified — an unprofitable product line and an unprofitable market channel exposed by the Whale Curve

Client Impact Results

• Decision: Executive Committee abandoned the replacement program based on projected total cost — honest advisory that saved the client from a failed initiative

Client Impact Results

• Executive Adoption: Framework anchored the CEO strategy session — "some of the best work to come across her desk" per the Global Pricing Leader

Client Impact Results

• Delivery: Roadmaps delivered against the TSA timeline; specific outcomes NDA-protected

Client Impact Results

• Outcome: Five entities stood up with 100+ applications; TSA exit tracking operationalized

• Savings: Millions in additional fees avoided for the PE client through risk mitigations (amount NDA-protected)

Client Impact Results

• Requirements: 669+ weighted across 12+ process domains and all affiliates

• Evaluation: 3 enterprise SaaS platforms scored quantitatively and qualitatively

• Financials: Complete NPV/IRR/TCO model with phased timeline

• Deliverable: CTO-endorsed business case and consolidation plan with implementation roadmap