CapEx/ Asset Utilization
Rapidly Pinning Down Capacity/CapEx, Manufacturing Cost, and Distribution Situation and Opportunities at Leading Dry Ice Manufacturer
Conducted 2-week operational due diligence to pin down capacity and CapEx situation, and to identify margin improvement opportunities in manufacturing, distribution, and branch operations ahead of a competitive auction bid. Created plant-specific profiles of 150+ pieces of production equipment and determined target had ample capacity for growth with minimal replacement CapEx risk. Analyzed and reconciled financial data from the target’s ~100 P&Ls and reallocated costs to establish true operational costs and production and distribution cost benchmarks across plants, branches, and routes and identified up to $6MM in margin improvement opportunities through disciplined distribution and pricing practices. Gotham’s due diligence enabled our client to move forward with a competitive bid.
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Rapidly Pinning Down Capacity/CAPEX Situation in Support at Premium Fresh and Frozen Food Manufacturer
Built a robust plant and equipment profile and comprehensive capacity model to provide client with understanding of true capacity picture in support of valuation assumptions for target in competitive bid process. Determined target could achieve ~3X stated capacity through minimal CAPEX; established 10% in quick-win cost savings available in labor, material, and overhead; and provided client with preliminary growth strategy utilizing co-packers, including targeted list of 9 potential co-packers interested in potential strategic alliance. Client moved forward with a more competitive bid based on Gotham’s capacity assessment.
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Determining Plant Closures and New Asset Placement at Large Consumer Goods Packaging Manufacturer
Formulated plant closure strategy and determined placement for the new printing assets by analyzing capacity, loading, customer logistics, and risks for each affected plant. Developed cost saving and one time cost scenarios. Developed business cases for two plant closures identifying $6.3MM in annual savings. Both closures were announced within weeks of the board's decision after the business cases were presented.
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Turning Domestic Operations into a Competitive Advantage at Leading Apparel Designer/Manufacturer
Devised a new supply chain strategy to leverage domestic manufacturing capabilities to decrease concept-to-market time by 67%, reduce inventory levels by 50%, and increase profits by 25%. Developed a dual supply chain strategy - market replenishment strategy for Basic products and market responsive strategy for Fashion products. Created a concurrent DFM product development process, and developed a flexible capacity allocation model for cut & sew facilities.
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