Manufacturing Footprint Strategy Builds the Case for Lower Cost, Higher-Throughput Operations

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The Challenge

A global manufacturer operating across more than 30 facilities was evaluating how to address excess footprint, duplicative labor, and inefficient production flow across its network. With lease timing creating pressure for a near-term decision, leadership needed more than a high-level consolidation concept. The company needed a clear view of the financial impact, investment requirements, operational risks, and payback period associated with consolidating work into a single location capable of supporting future growth.

The decision carried both cost and execution implications. Leadership needed to understand whether consolidation would generate enough value to justify the transition, how production continuity could be protected, and what operating model would best position the business for improved throughput and scalability.

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Our Approach

TriVista conducted a comprehensive footprint feasibility validation to test the consolidation opportunity from both a financial and operational perspective. The team assessed labor and facility costs, evaluated current site conditions, and analyzed production workflows to understand where space, labor, and process inefficiencies were constraining performance.

To quantify the opportunity, TriVista developed a future-state financial model comparing the existing network to a consolidated operating scenario. The model incorporated labor optimization, facility costs, utilities, overhead, and one-time investment requirements, allowing leadership to evaluate the business case across multiple execution scenarios.

TriVista also examined the practical realities of the move, including relocation requirements, production disruption risks, critical equipment needs, labor availability, real estate conditions, and potential incentives. These findings were converted into a phased implementation roadmap designed to reduce transition risk while enabling the business to capture savings, simplify operations, and improve production flow.

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The Results

TriVista provided leadership with a validated consolidation strategy that connected cost savings, operational feasibility, and execution planning into a single decision framework.

The analysis identified an opportunity to reduce total operating costs by approximately 8% to 14%, driven largely by labor optimization and an estimated 27% reduction in facility footprint. The future-state model also showed that consolidation could streamline production flow, reduce redundancy, and create a more efficient operating structure.

Depending on the execution scenario, the initiative was projected to deliver an estimated payback period of approximately two to four years. With a phased transition plan in place, the company gained a clearer path to pursue consolidation while managing production risk, protecting customer service, and positioning the business for scalable growth.