Post Acquisition Footprint Optimization

Business Situation

• Following a large-scale acquisition, the newly combined organization inherited two fully built global manufacturing footprints​
• Each legacy company had independently optimized its own operations, resulting in redundant capacity, overlapping regional facilities, and elevated operating costs.​
• The executive mandate: consolidate the footprint across North, Central and South America while protecting the customer.

Key Results

• 40% reduction in footprint by going from 15 plants to 9 plants​
• 45% reduction in headcount through productivity gains and consolidation​
• 100% customer continuity​
• Zero loss of revenue or orders​
• Improved margin through lower fixed-cost base