I Walked Into a $200M Manufacturer That Was Drowning

I walked into a $200M manufacturer that was drowning. Inventory accuracy was a disaster. Expediting charges bleeding money every month. Quarter after quarter, massive PPV swings tanking the bottom line.

Everyone assumed the system was the problem. They were already shopping for replacements.

Turned out production was changing BOMs on the fly. Sustaining engineering and inventory control never got the memo.

The system wasn’t broken. The rhythm was.

We worked through every BOM with the floor, processed the change orders, got everyone in sync. Everything started working.

Before you upgrade or rip and replace, check if your teams are actually talking.