Private Label/ Contract Manufacturing
Customer & Market and Operational Due Diligence of Private Label Canned Food Manufacturer: Establishing Growth Prospects, Margin Risk, CapEx Risk, and Operations Improvement Opportunities
In sync with the needs of each stage of the deal process, conducted phased customer, market, and operational due diligence, initially focusing on: 1) growth outlook – established the target’s category presence, identified key market trends, and built a model to project category growth; 2) competitive positioning – interviewed 27 PL and category buyers from supermarkets, wholesalers, food service companies, and brokers; and 3) CapEx and operational risk – visited the target’s 3 plants, assessed capacity, and reviewed operational improvement plans. After the client signed the LOI, Gotham conducted: a deep dive assessment of margin risk, using 7-year SKU-level price/margin data and outlook for major input cost drivers; and an in-depth operational diagnostic of material yield, direct labor, and inventory costs.
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Manufacturing Operations Improvements at Foodservice/Co-pack Juice Company: Network-wide Operating System to Turn Around Performance
Turned around plant performance by implementing basic plant operating system (downtime, waste, and scheduling). $600K in run rate cost savings captured by the end of the 6-week engagement, with tools and processes in place to capture the rest. Building on the initial success, rolled out the network-wide standard operating procedures to the other 2 plants during an 8-week Phase II effort with additional savings of $2-2.5MM expected. Company generating record EBITDA (60+% improvement in EBITDA) and the PE firm decided to market the company for an exit.
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Operations Diagnostic at Niche Beverage Co-Packer: Throughput and Cost Improvements to Become a Competitive Full-line Co-packer
2 week diagnostic that benchmarked conversion costs for the company and identified 15-20% in cost reduction opportunities. The effort indicated that with improved scheduling processes and more efficient use of labor, the company could save at least $1.5MM in the short-term. Recommendations also included putting in place a system to track true costs and performance to enable longer-term improvements.
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Manufacturing Operatons Diagnostic at Private Label Nutraceutical Company: Avoiding Need for Capital Investment via Throughput Improvement and Cost Reduction
Identified significant manufacturing capacity available through a variety of key throughput levers, including: reduced number and shortened length of changeovers; reduced frequency and duration of downtime; and increased speed in bottleneck equipment. In addition, identified 35% reduction in direct labor cost. Following our implementation plan, company increased EBITDA by $7MM by the end of the fiscal year and the PE firm successfully sold the company.
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Supply Chain Optimization at National Private Label Beverage Manufacturer: Better Forecasting/Planning and Performance Tracking to Turn Around Customer Service Performance
Developed key performance indicators, production planning logic, and inventory management policies for 11-plant manufacturing network. Implementation raised order fill rates to 98+% for key customers, increased volume by 37%, improved asset effectiveness by 40%, and reduced cost/case by 30%. Two client-side team members received corporate innovation award and $10,000 for their involvement in landing new account.
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