Consumer electronics products company

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Situation – Introduction of a blockbuster new product family generated very rapid growth overwhelming management and the small-company, informal infrastructure, as sales grew from $40 to $90 mil/year in a short period.

Actions Taken – we led multiple initiatives, collaboratively with the president & other leaders of the company:

·         Operations & supply chain leadership – recruited VP Operations and managers for production control, purchasing, warehouse, and an experienced manager for the newly designed & built production line.

·         Designed new, in-house production line to work around a whole series of design, technical, capability and capacity problems with the blockbuster new product.

·         Designed, built, implemented a new, full-scale ERP system with over 1,000 windows, 6,000 data fields enable the management of the company’s global, off-off and on-shore supply chain and global distribution system and unique business model.

Results – the rapid growth was achieved and sustained, with a functioning production & supply chain organization & system.  Highlights:

·         Sales grew from a run rate of $40 to $90 mil in less than 12 months.

·         Market penetration of the new blockbuster product was extremely successful; it became, for a time, the standard in the music recording industry globally.

·         The new production line was built in 3 weeks, ramped up from 35 units/day the first month, to 65/day the 3^rd month, then a sustained 125/day by the 4^th month and afterwards, adding $250,000 per day in sales from this product alone.

·         The new ERP system allowed a small team to schedule global, off-shore material procurement and plan production at both out sourced and internal production efficiently.