Distribution Center Operations Assessment Yields $36.4M in Savings

A rapidly growing $100M+ e-Commerce distributor with a large distribution network across multiple e-commerce platforms ran into capacity constraints due to lack of warehouse space and a large amount of slow-moving inventory, hindering their ability to meet expected growth targets Focus With over 7,000 SKUs and plans to bring on an additional 1,500+ SKUs per… Read More

Feasibility Study and Brownfield Delivers $12M in Savings Per Year

A private equity-backed $350M automotive manufacturing company suffering from production constraints was looking to augment production operations in North America by expanding into Mexico Focus The client was interested in expanding production to Mexico to create a strategic cost advantage, but had limited experience in Mexican labor rates, laws, real estate practices, government incentives, and… Read More

Sales, Inventory, and Operations Planning (SIOP)

Challenge A leading global provider of aerospace products faced decreasing inventory turns, high excess and obsolete inventory, and poor service levels. Key business issues described by management included: Forecasts of profit were regularly inaccurate Inventory turns were trending unfavorably High employee turnover While all these symptoms pointed to SIOP, there were several competing root cause… Read More

Inventory Reduction & Lean Roadmap

A $250 million machined aerospace structures company with seven global production facilities serving both military and commercial aerospace markets had made multiple acquisitions each year for several years and had significant discrepancies in operational performance from factory to factory (7 total). Many of the acquisitions had been long time family run businesses that had limited operational best practice implementation or adaption. As a result, several of the facilities were operating at sub-optimal performance level. The holding company turned to TriVista, leveraging our expert team to identify manufacturing and inventory opportunities within two production facilities representing approximately $140 million in sales. A key deliverable was to determine why these two facilities, despite exceeding growth expectations on topline revenue, were lagging on margin, EBITDA and cash flow performance compared to the remaining five sites.

China factory relocation

A successful, international manufacturing company was struggling with its existing China facility, comprised of multiple small warehouses and poor process flow. With growing domestic sales in China, the client decided to make a long-term investment in relocating to a new facility with improved production flow and room for expected growth. Recognizing that our client faced multiple deadlines with their customers and landlords, TriVista was committed to meet our client’s needs while adapting the project schedule to best fit the changing order flow. Communication was essential, requiring input from both American and Chinese stakeholders in multiple languages to conduct the feasibility study, select the new facility, make necessary improvements and manage the relocation.

Factory relocation & greenfield startup

TriVista guided a large automotive manufacturing company through the process of establishing a new facility, which included a multi-region feasibility study, comprehensive project design, and a strategic implementation plan.

Lean implementation – Industrial equipment

TriVista led efforts to drive process improvement, expand capacity and reduce inventory at a leading industrial equipment manufacturer. The Business Challenge TriVista’s client was a private equity owned $65 million manufacturer of industrial equipment.  The company was trying to explore ways to increase capacity without adding additional roofline – max capacity was reached at their existing… Read More

Lean manufacturing in the automotive industry

Orchestrating Process Improvement in an Automotive Component Factory Company Confidential is a privately held $100 million manufacturer of specialty advanced technology heat exchange devices for the automotive, truck, and mobile equipment market. Company Confidential serves both commercial and military markets, with market segments ranging from general passenger vehicles, light duty trucks, heavy equipment, personnel transport,… Read More

Manufacturing optimization & lean implementation

Leveraging TriVista’s Lean Six Sigma expertise, the client was able to generate $2 million in EBITDA and reduce working capital by $6 million. The Business Challenge A $65 million consumer audio electronics manufacturer specializing in high end luxury audio components was facing decreasing sales and declining margins. Although their products are sold through the largest… Read More