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Operational Excellence Results in $1.9 Million Cost Savings


Consumer goods Manufacturer wanted to downsize their facility footprint while weighing several options to truly make their operations excellent.

They need extra arms and legs to drive this initiate to downsize, outsource, and specialize internal departments and areas. This CGM produces products in the consumer, professional, and transportation safety industries and needed to maintain or exceed current customer levels of satisfaction.


The MetaExpert™ weighed several options to further optimize our customers operations after an observation period involving Gemba walks, critical path analysis, and risk management assessments while considering the following possible customer goals:

  1. Move the administrative team to a different facility.
  2. Outsource some manufacturing to subcontracted companies to lessen onsite facilities.
  3. Transition all internal manufacturing operations to one sole facility.


After our MetaExpert™ formed and chaired three departmental teams in the production, logistics, and administrative areas; collaborated with decision makers and further assessed the costs and benefits of all options.  Collectively these three actions were implemented:

  1. Outsourcing some manufacturing and labor.
  2. Consolidate the current scale of administrative and manufacturing teams now in different facilities.
  3. Rent the now vacant manufacturing and production spaces to generate a new revenue stream.

Return on Investment

  • $1.9 million in projected cost savings from downsizing
  • Training and mentorship of internal teams on operational excellence and process management to further insource ongoing improvement procedures
  • Creation of new revenue stream from renting out now vacant production facilities
Outsourcing product lines yields savings

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