TriVista Advises Leading Aerospace Manufacturer on Plant Consolidation & Layout Optimization; Delivers $3.5M EBITDA Savings

The Challenge

A $750M global manufacturer of highly specialized, aerospace parts was seeking assistant in determining a consolidation strategy for their underutilized plant in the Midwest. TriVista was retained to provide operations consulting expertise and assistance in modeling and planning the consolidation effort.

Our Approach

• Conducted a rapid three-week assessment of the underutilized facility to understand the costs, benefits, and challenges of transferring operations into the clients other four plants
• Created multiple options for new, more effective plant layouts
• Performed detailed financial analysis to determine if hypothesis was feasible
• Worked closely with management team to identify one-time and on-going costs
• Calculated annual savings/cost impact of relocating existing sites
• Identified necessary close procedures, severance options and relocation assistance plans
• Developed project timelines with major milestones for each workstream

The Results

• Identified approximately $3.5M of annual EBITDA opportunities by rationalizing footprint, optimizing new facility layout, and eliminating underperforming low margin products