EMS Equipment Manufacturer Identifies 8–14% Cost Savings Through Multi-Site Consolidation
Overview
A manufacturer of tourniquets, trauma kits, and other emergency medical services (EMS) equipment engaged TriVista to evaluate and design a multi-site manufacturing consolidation strategy aimed at reducing operating costs, improving throughput, and supporting long-term growth.
Operating across more than 30 global facilities, the company faced increasing complexity driven by excess manufacturing footprint, duplicative labor structures, and inefficient production flow. Leadership needed to rapidly assess consolidation opportunities while balancing operational risk, investment requirements, and business continuity considerations.
TriVista developed a future-state manufacturing network strategy and financial model that identified significant cost savings opportunities while establishing a phased implementation roadmap designed to minimize disruption.
The Challenge
The manufacturer operated across a large global manufacturing footprint that had evolved over time through growth and operational expansion. As a result, the organization experienced:
- Excess facility footprint and underutilized space
- Duplicative labor and overhead costs
- Inefficient production flow across multiple locations
- Operational complexity impacting scalability and throughput
- Near-term lease timing constraints requiring rapid decision-making
Leadership needed a clear understanding of the financial impact, execution risks, capital requirements, and payback timeline associated with consolidating operations into a more optimized manufacturing network capable of supporting future growth.
Our Approach
TriVista conducted a comprehensive manufacturing footprint feasibility and operational assessment across the company’s facility network.
The engagement included:
Manufacturing Footprint Analysis
- Facility and labor cost benchmarking
- Site assessments and workflow analysis
- Capacity and production flow evaluation
- Identification of operational redundancies and inefficiencies
Financial Modeling & Scenario Analysis
- Development of future-state consolidation models
- Comparative analysis of current vs. consolidated operations
- Evaluation of labor optimization opportunities
- Analysis of facility, utilities, and overhead cost reductions
- One-time investment and implementation cost assessment
Risk Mitigation & Transition Planning
- Assessment of relocation and production risks
- Critical equipment and operational dependency analysis
- Labor market, real estate, and incentive evaluation
- Development of a phased implementation roadmap to reduce disruption and execution risk
The Results
TriVista identified a significant opportunity to improve operational efficiency and reduce manufacturing costs through facility consolidation and labor optimization.
Key Outcomes Included:
- Approximately 8–14% reduction in total operating costs
- Approximately 27% reduction in facility footprint
- Improved production flow and operational throughput
- Reduced redundancy across labor and support functions
- Estimated payback period of approximately 2–4 years depending on implementation scenario
- Enhanced scalability to support long-term business growth
- Reduced execution risk through phased transition planning
The engagement provided leadership with a data-driven consolidation strategy and implementation roadmap that aligned operational improvements with EBITDA performance objectives.