Strategic Planning

Group50® manufacturing & distribution consultants have done hundreds of major projects during their careers and as consultants for many large and small companies which demonstrate our ability to support a manufacturing or distribution client for any of its needs throughout its entire life cycle. In the list below, click on the category headline to see a few examples of projects we have done.

Strategic Execution


  • Worked with the Board of Directors of a home manufacturer on governance issues they were facing.
  • Developed and began the implementation of a 5 year customer service plan for a $80MM/yr. medical device company with operations on 3 continents.
  • Wrote a business plan with a full set of financials for an EB-5 investment project for a hotel, land and a restaurant.
  • Developed a manufacturing and distribution strategy for a medical device company that included both in-sourcing and out-sourcing.
  • Created a strategy for a medical device company to increase their production 50 fold designing a cellular approach that allowed them to easily move production capacity around the world.
  • Facilitated a multi-day meeting with a $250M publicly traded company to define their 3 year strategic plan objectives
  • As interim CEO Automated Wheel Finishers, a start-up manufacturer of complex finishing systems for automotive wheels, I was recruited by the board to assess the viability of the company’s product. They had lost all of their customers, so we focused on business development, and completing an analysis of the technology of the company and its capabilities to deliver projected results.
  • Executive Chairman with Pankl Aerospace, a manufacturer of rotating flight safety parts. Engaged by corporate parent to work with management team to implement best practices and significantly improve the performance of the supply chain.
  • Board member with Green Wireless Systems, a wireless technology start-up company for the irrigation industry. Worked with the company to develop their go-to-market plans, technology platform and funding strategies.
  • Developed a business plan and operational system for a Business to Business Peer network called The Global Leaders. Provided business development expertise, product/services road map and business plan.
  • Completed a business review of a $30M precision machining Aerospace company
  • Strategic Supply chain review for the U.S. Postal Service. Created and delivered a 3 day Cost and Price Analysis
  • Worked with a medical device manufacturer developing and implementing a long term organization strategy, new processes and a redesign of their supply chain to enable them to successfully navigate significant growth
  • Worked with a polystyrene recycling company to develop its business plan, start-up strategy and go to market plans

Integrating Acquired Companies

  • Worked on the integration of a convention company developing organizational design recommendations.
  • Worked on integration of Coleman, First Alert, Mr. Coffee and Health-o-Meter into Sunbeam. Project included development and implementation of synergies, organization staffing and cultural integration
  • Part of integration team of Emhart into Black & Decker, with a focus on business processes, sales integration and implementation of corporate reporting systems for operations
  • Integrated Champion Irrigation into Arrowhead Brass. Integrated manufacturing and distribution. The Integration of sales and marketing required a full redesign of go to market plans, pricing models and integration of customer accounts into one system.
  • Integrated two acquired materials converter companies into parent, establishing new organizational structure and consolidated facilities. Halted market attrition of prior entities. Combined companies became a market leader in materials conversion within 24 months
  • Acquired a key materials supplier and integrated it into the parent company generating $2+M in operating profit gains, improving systems and business process with no significant loss of key personnel
  • Integrated finance organization and financial reporting systems for Qwest Communications’ acquisition of U.S. West Communications.
  • Worked on the acquisition of a chemicals mixing operation in Ohio with a focus on gaining more Midwest presence for client. Completing due diligence, integration planning and environmental study

Financial and Operational Restructuring

  • Advised a publicly traded company on how to restructure itself to optimize its financial performance.
  • Recovered 90% of lost schedule and $1.0M in overruns on a $10M product initiative
  • Led the effort to turnaround an Aerospace company through process and supply chain redesign
  • Restructured a $200M consumer product business in less than 18 months, realizing 15% improvement in profitability in the first year
  • Financially restructured a consumer products company while keeping all of the original investors in the ownership structure
  • Consolidated operations in a consumer products company to a single plant and new DC. Redirected its sales effort to retail, increasing sales 50% in that channel of distribution
  • On a contract basis, stepped in to initiate a turnaround of a struggling $25M/year producer of residential and commercial heating systems. Within 3 months, had stabilized the business, moved toward breakeven, and started to reorganize the operation for the successor permanent manager.
  • As general manager of this industrial products company, returned this $8M plant to profitability. Successfully negotiated first ever labor agreement, and reduced headcount by 20% to save over $600K costs.
  • As president, directed the turnaround of an $11M truck body and equipment manufacturer/distributor. Regained profitability from two-year loss of $1.5M to $176K profit through focus on shipments and cost management. Renegotiated lines of credit to establish new product lines and engineering improvements.

Business Process Re-engineering

  • Completed a review of the customer service organization and its business processes utilizing Value Stream Mapping (VSM) and made over 40 recommendations regarding ways to streamline the customer service processes and leverage existing and new technologies.
  • Re-designed and implemented a “Delivery Review Board” process for a company that designs and produces highly engineered products for customers around the world. This process covered all activities from Tender through to site acceptance.
  • Re-designed the process for scheduling products at multiple plants
  • Led the transformation of an enterprise MRP system from batch manufacturing to continuous flow manufacturing
  • Redesigned the product development process in several middle market companies significantly reducing time to market and strategic focus
  • Converted fully manual system into an SAP/MRP–driven process for distribution from over a dozen global manufacturing sites to a nationwide network of 19 public warehouses in highly seasonal $300MM crop protection chemicals business.
  • Designed/delivered global platform for customer complaint management, with dashboards and Quality Scorecards for a multi-billion dollar corporation and by business:
    1. Complaint rate for service and documentation issues dropped 36% (1.4% of deliveries to 0.9%)
    2. Warranty payments granted for quality issues dropped 50% (0.32% of sales to 0.16%).
    3. Resolution timeliness improved by 40%, Closure timeliness improved by 55%

Manufacturing and Distribution

Continuous Improvement

  • Completed a review of the customer service organization and its business processes utilizing Value Stream Mapping (VSM) and made over 40 recommendations regarding ways to streamline the customer service processes and leverage existing and new technologies inside a $80MM/year medical device company.
  • Created a Value Stream Map for a $400+M company with locations around the world and identified $14M in immediate and short term cost savings.  Recommended multiple organization and system strategies that would significantly increase throughput and reduce lead times in critical business processes. Recommended multiple projects aimed at taking out 45% of inventory as well.
  • Developed and implemented a company wide program for a battery pack manufacturer to restructure its manufacturing operations utilizing lean techniques: one piece flow, production on demand, Kanban and trained the operations and manufacturing team on DFM techniques.
  • Reduced product lead times from over 100 weeks to less than 50 in an aerospace company and significantly improved the reliability of their supply chain.
  • Project to review the performance of a plant for Bodycote, a worldwide heat treating company. Identified a series of changes implemented during the project which realized significant improvements in efficiency and customer service.
  • Organizational review for a multi-plant bakery and summary performance reviews of each plant and their operations
  • Led 5 Kaizen events in a OEM manufacturer realizing over $1M in annual savings, a significant reduction in working capital and move toward on demand production
  • Led over 40 Kaizen events in a $400M manufacturing facility and was the one of three US training facilities for Shingijutsu
  • Worked with Mexican, Far Eastern, European and US Operations introducing Kaizen and standardized push/pull inventory improving productivity over 20%
  • Introduced ‘Kaizen’ lean manufacturing improvement processes at a consumer durable factory, reducing labor cost $850K, improving finished product quality by 50% and creating 23K square feet of manufacturing space for needed manufacturing expansion.
  • Implemented a ‘lean manufacturing’ approach to an industrial product’s operation, allowing for management and consolidation of an aged New England plant. The consolidation and relocation of operations to North Carolina was completed without creating market or cost disruptions. Eliminated redundant costs of $1.7M.
  • Developed ‘just in time’ delivery process to increase service levels to +98% on an expanded industrial products business (over 3000 SKU’s) by developing strategic kanban inventory and fast turnaround manufacturing processes.
  • Implemented lean manufacturing processes at two different SE Asian manufacturing operations, achieving 15 – 20% yearly improvements in labor, and more than 5% annual cost savings
  • Spearheaded the creation of a Quality Practices Assessment Tool, defining simple criteria for evaluating compliance with 20 key business practices critical for delivering lower complaint rates, higher on-time shipments, excellent quality results, and capability for more reliable innovation and used to drive Quality Manager commitments.
  • Constructed and administered the “TQ Appraisal Survey” as pre-cursor to factory re-design efforts in the move toward becoming a “high-involvement” organization, published in ASQC’s Quality Progress in November 1991
  • Re-designed the QC test organization to expand responsibilities and increase efficiency. Plant output increased by over 50% while department size dropped by 14%, and morale improved
  • Reduced test failures from over 30% to 0% of glass spheres produced for the Navy by Corning Glass Works..

Supply Chain Rationalization

  • Completed a Value Stream Map for a global manufacturing company with operations in the US, Far East and Europe. Identified greater than $10 million in cost and working capital reductions, while decreasing lead times for product by 75%
  • Completed a total cost of ownership study: Mexico vs. China for a middle market medical device company.
  • Implemented a supplier scorecard system in a globally sourced supply chain. Scorecard consisted of quality, cost effectiveness, lead time reduction and continuous improvement KPI’s
  • Improved inventory turns in a global company from 4 to 16 in two years
  • Implemented training courses for a supply chain team to teach them how to manage a multi-distribution supply chain
  • Implemented a strategy to move production to Mexico and convert a medical device company’s distribution operations to a muli-location 3PL provider in both the US and Europe.
  • Redesigned the North American supply chain strategy (manufacturing and distribution) for a company that yielded significant reduction in COGS and distribution costs.
  • Completed a study of manufacturing cost effectiveness in 89 countries
  • Developed and implemented a program to add more off-shore suppliers for a manufacturing company, reducing risk and cost.
  • Significantly reduced total cost for a manufacturer by identifying multiple design and manufacturing partners in both Mexico and China. This lead to a significant reduction in lead time for new products
  • Created a manufacturing strategic plan for a medical device company to significantly increase their production of a needle free syringe to over 100 million units per year, which included domestic and off shore programs.
  • Led Sunbeam’s rationalization project, reducing the number of distribution and manufacturing facilities from 26 to 14
  • Planned and executed the move of Black & Decker’s US based appliance manufacturing operations to China and Mexico
  • Consolidated 3 plants into a greenfield site for a private equity group. Developed project management schedule, line layouts, rationalization of product lines and machining/assembly centers.
  • Established a standalone Hong Kong Company, with engineering, quality assurance, program management and logistics functions, to manage the $70M/year S.E. Asian sourced products purchases for a large consumer product company’s North American markets.
  • Directed a multi-site manufacturing transfer program, moving $170M/year of manufacturing volume from a consumer products U.S. facility to Mexican and Chinese operations – $24M project with estimated savings of $10M/year – completed on time and 7% under budget.
  • Developed and implemented a contract manufacturing business plan, developing over $30M in annual sales for North American customers not experienced in SE Asian sourcing. Located and developed network of capable, cost competitive suppliers in SE Asia in areas of industrial and consumer durables, electronics, plastics, materials, toys, offering turn-key product development and program management of complex new projects, using proven engineering, development, and manufacturing partners.
  • Led product development, sourcing, and program management activities for 22 new consumer products to be introduced in 2004/05. Working with domestic engineering, marketing, design, and suppliers in SE Asia, on track to successfully complete this $5M project.
  • Designed and implemented a new facility to produce components for houseware products in Malaysia
  • Consolidated operations in a consumer products company to a single plant and new DC
  • Black & Decker master scheduling process improvement results (lean/JIT manufacturing site in Queretaro, Mexico):
    1. Expanded role from handling 2 dozen US skus in 3 product lines to 170 skus across 12 product lines for both North and South America over a 3-year period.
    2. Increased inventory turns by >50%, reduced out-of-stocks by 30%; reduced time to issue manufacturing’s daily shipment schedule from 25 days to 12 & created customized reports for each commercial office.
  • Cycle Time Reduction for R&D/Commercialization process: Created new collaboration platform and reduced cycle time from 6+ weeks to less than 5 days for Commercial Teams to request new SKUs and production trials.

Cost Improvements

  • Relocated manufacturing operations in Europe, Southeast Asia, North America and Eastern Europe for faster supply chain response, resulting in 50% landed cost reductions
  • A major consumer product company had high quality costs and poor packaging design that lead to dissatisfaction at the retail location. Designed an internal and external product effectiveness audit that led to a re-design of the product line addressing these issues, reducing quality costs by 75% and calls/100 units by 90%.
  • Created an offshore Center of Excellence (CoE) from the ground up including people redeployment and implementation of service level agreements (SLA)

Capital Project Management

  • Created a manufacturing strategic plan for a medical device company to significantly increase their production of a needle free syringe to over 100MM units per year, which included domestic and off shore programs.
  • Designed and project managed the implementation of a new plant to manufacture safety razors in the Chzek Republic
  • Developed and implemented a $10M program to redesign a high volume packing and distribution facility
  • Designed and implemented a distribution center for a medical device company

Market Effectiveness

Product and Portfolio Management

  • Developed and implemented a global new product management system to organize and manage over 300 new product development products at a consumer products company worth more than $200 M/year in incremental business
  • Designed and implemented product manager training at large consumer products company training over 25 new product managers
  • Implemented and broadened application of a “razor/blades” strategy for a leading consumer products company, applying an extremely successful strategy from one business to a “sister” SBU. Efforts vitalized the targeted business to accelerate sales to double-digit growth and a much-strengthened brand.
  • Developed and launched a line of new, innovative “social expression” products, helping a leading office products company move from simply functional products into higher-involvement products, strengthening its brand accordingly.
  • Implemented a program called the “Product Lifecycle Revenue Model” which focused on product revenue generation throughout its total lifecyle….. sale to end of life
  • Reviewed the product programs for a middle market hi-tech company and implemented a program to pare under-performing products from their portfolio to free up resources inside the company, improvement profitability and focus on the product platforms that were going to provide sustained growth

Product Development and Implementation

  • Worked with the UK operations of a multinational company to get a $100M highly engineered product program into production. Resolved several critical design and manufacturing issues that existed in the product and in 4 short months the business was able to ship 3 times as much product as they had built in the previous 3 years.
  • Program managed a $13M product program in the consumer products industry that was $1.0M over budget and 6 months behind schedule. Worked with a US based product division of a large multinational company and its Mexico source to bring the project in on time and on budget.
  • Worked with a PE backed start-up as the interim CEO in the automotive industry to develop an effective product strategy, complete the design and test product effectiveness.
  • Led a team in a $220M seasonal consumer product business to redesign its full product portfolio and designed and implemented a flow manufacturing strategy to support it resulting in a $30M swing in profitability over an 18 month period.
  • Designed and Implemented a $15M new product program which resulted in the most successful product launch in Black & Decker’s history. This project include complex molds, automation and high volume production.
  • Developed application-optimized products, branding, packaging, communications and specialty retail distribution for a formerly pure-play B2B products company. Efforts drove extensive new distribution and retail “billboard effect” strengthened the company’s brand, with benefits spilling over into its other lines.
  • Implemented a multi stage gate product development process that focused on the proper ideation and justification of new product programs resulting in a 25% reduction in development to sales lead times


  • Implemented an Internet based sales system providing online exposure of long tail product items increasing total product sales by over 10% the first year.
  • Created the brand strategy for the combination of two companies in different market segments with similar sales channels
  • Developed the strategic plan, customer pitch and website for an Asia-focused logistics and packaging company, enabling the client to better serve its mega-retailer customer and earn more of its customer’s business.
  • Revamped a client’s merchandising strategy, improving shopability, brand and on-shelf impact. Strengthened the client’s related environmental/“green” positioning.


  • Consolidated operations in a consumer products company and redirected its sales effort to retail, increasing sales 50% in that channel of distribution
  • Completed the implementation of a manufacturing representative system creating sales representation for a plumbing and irrigation products company throughout North America
  • Implemented a full sales dashboard reporting on sales trends, customer profitability, portfolio profitability and sales group performance
  • Created a long term sales strategy for two separate channels of distribution that often dealt with the same customer base
  • Created and implemented a single pricing strategy for two companies that were acquired and integrated
  • Revamped Sales and Customer Service structure to better serve targeted markets and reduce costs. Re-set Sales compensation program to align with company capabilities and strategy, whereas former scheme put Sales emphasis at odds with company’s manufacturing and sourcing capabilities.
  • Developed the first, comprehensive and formal account planning process for a chemicals compounder, tying related account plans into business’ annual financial plan and establishing related customer sales accountabilities. In parallel, established an effective account strategy process tied to company strategy and goals.

Organizational Development

Performance Management

  • Implemented a performance management system as a business strategy for a publicly traded company, utilizing the approach as outlined in our article: Performance Management As A Business Strategy
  • Organizational review for a multi-plant bakery and summary performance reviews of each plant and their operations
  • Implemented performance management systems in the following industries Software, hi-tech, CPA, Insurance, Franchises, Asset Management
  • Coaching senior executives on how to successfully navigate significant growth and organizational development


  • Implemented a company wide survey as part of the process for integrating two companies, resulting in the basis for developing a plan to deal with divergent cultures.
  • Implemented a survey of a marketing and sales organization to understand the the Voice of the Customer for a medical device company,
  • Surveyed employees from 9 countries for a client to facilitate understanding of employee mindset, cultural traits and management effectiveness
  • Developed a fully automated 360° evaluation tool

Learning Maps

  • Developed learning maps for the supply chain members of the US Postal Service with a focus on the required skills to be a career professional, manager and senior executive. See article for more information on the utilization of learning maps to grow your future leaders, click here.
  • Created and implemented a training and development program for a supply chain organization in a medical device company. The program included professional and leadership development programs as well as job progression plans for various functional positions.
  • Created customized supervisory training program that was incorporated into round-the-clock manufacturing environment, avoiding over a half-million dollars in purchases from established vendors.

Global Initiatives

Offshore Manufacturing

  • Designed and implemented a new facility to produce components for housewares products in Malaysia
  • Moved operations from the US to a Mexican Shelter company saving over $1.0M
  • Directed a multi-site manufacturing transfer program, moving $170M/year of manufacturing volume from a consumer products U.S. facility to Mexican and Chinese operations – $24M project with estimated savings of $10M/year – completed on time and 7% under budget.

Contact us

Jim Gitney

(909) 949-9083

Jim Gitney, the CEO of Group50® Consulting, has over 30 years of operational experience in companies ranging from start-ups to Fortune 50 in many industries. He brings a unique view of how business is structured, measured and improved. Jim has served as a Chairman, Board Member, CEO and worked many C-Level executive and operational roles including financial and operational turnarounds.

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