Site Consolidation

$200M Gift Card Manufacturer

Background

  • A private equity backed $200M gift card manufacturer with 5 locations
  • Newly acquired facility in California with $40M in revenue to be closed and moved to an existing location
  • Private equity investment thesis of reducing rent and labor costs while maintaining sales

Contributions

  • Established steering committee to drive progress
  • Detailed Gantt Chart with every piece of machinery that was moving with an unplug, pick-up, drop-off, and operational date
  • Created skills matrix to begin cross training and allow for adaptability to withstand headcount reduction
  • Created a quality check matrix for closing the facility

Results

  • Within 45 days, aligned operational and financial reporting
  • Revenue was retained with a headcount change from 300 to 180 employees
  • Removed risks of move by assigning responsibilities of plant improvements, machine move, and machine set up to individuals
  • Set up a playbook for determining quality functions within each facility to replicate in any new facility