75+ Process Gaps Identified Root Cause Found Upstream
Leadership suspected Order-to-Cash issues. Our assessment revealed the real problems were upstream in Forecast-to-Fulfill—a discovery that redirected improvement efforts toward root causes rather than symptoms.
Result at a glance
"We're like two different companies instead of one, and we're not working together."
What We Found
Through intensive two-day onsite workshops with cross-functional teams, we documented the real operational picture:
Critical Gaps Included
• Production planning managed through 20+ Excel worksheets outside ERP—single point of failure
• 100% manual order entry creating data errors and rework
• No demand forecasting; production entirely reactive to orders
• No CRM or EDI integration; institutional knowledge trapped in email
What We Delivered
Quick wins for immediate impact: Daily cross-facility coordination calls, standardized document workflows, shared production schedule visibility, and structured handoff protocols—all implementable without system changes.
Strategic roadmap for transformation: S&OP framework with designated cross-facility coordinator, technology integration evaluation, organizational clarity with ownership accountability matrix, and KPI framework including On-Time-In-Full metrics.
The Outcome
The organization shifted from chasing symptoms to addressing root causes. Leadership now has a shared understanding of process interdependencies, a prioritized improvement roadmap, and the cross-functional visibility needed to operate as one unified company.
Better Built Doesn't Happen by Accident
Growth created complexity. Complexity is costing you. The path forward starts with a single conversation.
