Sell-Side Operations Assessment Validates Capacity for 2–4x Growth and Highlights Value-Creation Upside

---

The Challenge

A global manufacturer preparing for a potential sale needed to show prospective buyers that recent operational improvements were translating into measurable performance gains and that the manufacturing network could support continued growth without major near-term infrastructure expansion.

Leadership also wanted to demonstrate that the business was evolving from a collection of individual facilities into a more integrated enterprise operating model, with stronger governance, shared best practices, and greater scalability across the network.

---

Our Approach

TriVista conducted rapid operational assessments across three manufacturing facilities using its proprietary manufacturing benchmark to evaluate safety, quality, performance, layout and flow, equipment, continuous improvement, inventory, teamwork, and capacity.

The review examined the impact of recent changes already underway, including leadership enhancements, facility redesigns, tiered daily management, SQD metrics, visual controls, standardized work, cross-training, and Kanban systems. TriVista also evaluated broader enterprise capabilities such as the global Quality Management System, U.S. Kanban model, site-level capacity, sourcing, production planning, inventory practices, and SIOP maturity.

This allowed TriVista to do more than validate current performance. The team also quantified the amount of growth the existing network could absorb and identified additional opportunities to improve working capital, lead times, inventory visibility, and operating consistency.

---

The Results

The assessment demonstrated that the company had developed a strong and increasingly integrated operating platform, with proven practices being shared across facilities while preserving the flexibility required for different products and regulatory environments.

Operational gains were supported by measurable results, including an 11% increase in revenue per operational headcount over three years, approximately 99% first-pass yield, and improvement in U.S. on-time delivery from roughly 97% to nearly 100%.

TriVista also confirmed substantial growth capacity within the existing footprint. With additional shifts, available space, selective equipment investment, and targeted labor additions, individual sites were capable of supporting approximately two to four times current output, reducing the likelihood of significant near-term capital expansion.

The review also surfaced additional value-creation opportunities, including the potential to reduce legacy component inventory by approximately 31% through turnkey procurement and improve inventory performance through stronger supplier MOQ controls and structured reduction programs.

By translating operating improvements into clear evidence of performance, capacity, and future upside, TriVista helped strengthen the company’s sell-side positioning and gave prospective buyers a more complete view of both current operational maturity and post-close value-creation potential.