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

Operational Diagnostic -Food manufacturer achieves $500K in annual savings

Leveraging TriVista’s Lean & Process Improvement Expertise, the client was able to generate $500,000 dollars in savings. The Background The largest provider of fresh deli solutions, TriVista’s client makes fresh salsa, dips, and hummus for consumers sold through major retail chains. Their product can be seen on grocery store aisles across the country and they… Read More

Supply chain & inventory improvement

TriVista dramatically improved customer service by implementing a robust Sales, Inventory, and Operations Planning (SIOP) Process that decreased stock-outs by 50% without additional inventory. The Business Challenge TriVista’s client was facing increasing backorders and rapidly declining customer satisfaction. Our team was tasked with developing an improved supplier and inventory management system which would eliminate stock… Read More

Warehouse layout & flow optimization

TriVista optimized the layout of a 50,000 sq. ft. warehouse for a leading consumer products company The Business Challenge A private equity owned consumer products importer wanted to improve warehouse efficiencies, reduce material movement and improve product flow inside their new 50,000 sq. ft. facility. TriVista was retained to design an optimized facility layout and… Read More