Operating Model Redesign Identifies 8%–14% Savings and Strengthens Three-Site Consolidation Case

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The Challenge

An emergency response technology and training products manufacturer was evaluating the consolidation of three geographically dispersed business units into a single facility. An earlier footprint study had established the basic feasibility of consolidation, but leadership recognized that simply relocating the three operations would leave significant value on the table.

The company needed to define how the combined organization should operate in the future—across people, processes, planning, production, inventory, fulfillment, and governance—while preserving service continuity and creating room for future product launches and growth. The goal was to turn a real estate decision into a broader operating model redesign.

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Our Approach

TriVista began by mapping the current-state processes and organizational structures across all three business units, then used that baseline to design an integrated future-state operating model.

The work spanned organizational design, production, procurement, planning, inventory, fulfillment, capacity, material flow, and operating management. By looking across sites rather than within them individually, TriVista surfaced duplicated responsibilities, opportunities to centralize work, and ways to improve labor utilization that would not have been captured through facility consolidation alone.

The team then converted the future-state design into a detailed execution plan. This included an approximately 11-month transition schedule, governance and resource requirements, facility specifications, budget and cash flow planning, risk mitigation, and production and inventory transition strategies.

As part of the redesign, TriVista also reassessed the facility requirement itself. The analysis showed that increasing the target footprint from approximately 50,000 to 65,000 square feet would provide greater operating flexibility and support future growth with only a modest impact on the modeled return profile.

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The Results

The engagement gave leadership a consolidation strategy built around how the business should operate in the future, rather than simply recreating three legacy organizations under one roof.

The redesigned operating model identified approximately 10%–12% labor savings through organizational consolidation and the elimination of cross-site overlap. In total, modeled operating cost savings ranged from approximately 8% to 14%, creating a materially stronger economic case for consolidation.

TriVista also demonstrated that the larger facility option could better support future product launches and capacity needs while adding only about two months to the modeled return on investment. Across the scenarios evaluated, the consolidation was projected to achieve an approximately 1.7- to 3.5-year payback.

With the future-state model, financial case, and implementation roadmap in place, leadership was able to move forward with facility evaluation and prepare a more robust consolidation recommendation for board consideration.