Transformational Operations & Capacity Expansion Drive 53% Margin Improvement

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The Challenge

A large racking manufacturer was pursuing a significant growth opportunity but lacked the operational capacity and facility strategy to support it.

The company operated multiple facilities across a mid-sized geographic market, resulting in elevated transportation and labor costs, fragmented production flows, and persistent bottlenecks across key processes. These constraints limited throughput, impacted delivery performance, and reduced overall efficiency.

At the same time, leadership faced two parallel priorities:

• Short-term: Rapidly increase production throughput to fulfill near-term incremental demand
• Long-term: Evaluate the feasibility of consolidating operations into a single, more efficient facility to support scalable growth

The organization required a clear current-state production roadmap, along with a data-driven facility strategy, to balance immediate performance improvement with long-term footprint optimization.

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Our Approach

TriVista implemented a targeted operational transformation focused on unlocking near-term capacity while establishing a foundation for sustainable performance.

The engagement began with identifying key production bottlenecks, particularly in weld and paint operations. Rapid improvement initiatives were deployed to rebalance labor, standardize workflows, and reduce changeover times—immediately increasing throughput.

TriVista established a structured Operational System to drive daily performance management, including:

• Standardized metrics and visual management
• Leader standard work and accountability routines
• Structured problem-solving to address constraints in real time

Additional initiatives included:

• Optimizing paint line performance by reducing variability and outsourcing non-core products
• Improving machining, roll forming, and robotic welding capacity within the existing footprint
• Implementing make-to-stock strategies to stabilize scheduling and reduce stockouts on high-volume products
• Executing rapid improvement events that delivered 50–100% output increases in targeted areas

To support long-term growth, TriVista conducted a comprehensive footprint and capacity strategy, including:

• Facility relocation analysis and build-to-suit planning
• Detailed layout design incorporating production flow, storage, and material movement
• Capacity modeling aligned to future demand and growth projections
• Development of a phased 18-month implementation roadmap

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The Results

TriVista’s integrated approach delivered immediate performance improvements while positioning the organization for scalable growth.

• 53% contribution margin improvement achieved within the first year
• 50–100% increases in output across key production areas
• Elimination of critical production bottlenecks, enabling improved throughput and delivery performance
• Implementation of a scalable Operational System driving ongoing performance visibility and accountability

Additionally, the client established a clear path for expansion:

• New facility identified to support 70% increase in top-line revenue capacity
• Defined roadmap for footprint expansion and long-term operational scalability