CASE STUDIES
CASE STUDY #1
Operational Due Diligence Unlocks $30M+ Growth Potential
An investment bank evaluating a $130MM industrial manufacturer requested a clear view of operational risk before acquisition. OptaProfit completed a focused diligence that revealed hidden issues and concrete levers for value creation.
THE CHALLENGE
Despite available capacity, the target facility was constrained by weak quality systems, inconsistent forecasting, minimal lean practices, and energy infrastructure at 97% utilization. Without intervention, these issues threatened profitability, scalability, and valuation.
OUR APPROACH
We ran a hands-on operational review focused on what moves outcomes.
Quality Systems
Tracked cost of poor quality. Reviewed audit discipline and closure of corrective actions.
Mapped defect taxonomy to Pareto drivers on top products.
Delivery Performance
Measured on-time delivery against customer promise dates. Investigated calibration bottlenecks.
Benchmarked forecast accuracy and demand signal flow to production planning.
Productivity and Lean Practices
Assessed Lean Daily Management, visual controls, and floor-level metrics.
Walked value streams end to end to find wait, rework, and changeover loss.
Infrastructure and Strategic Risks
Audited energy capacity and reliability. Reviewed automation readiness by line
Screened environmental and compliance exposures tied to planned growth.
Recommendations focused on root cause tracking, stronger demand forecasting, daily lean routines, and an energy capacity plan.
CLIENT'S VOICE
βThe diligence gave us clarity on risk and upside. Donβs assessment helped us price the deal correctly and see how much operational value we could unlock after close.β
Questions about an active deal or a target you are screening? Visit optaprofit.com/consult
CLIENT SNAPSHOT
Industry: Industrial Manufacturing (Confidential)
Size: $130MM current volume, $165MM capacity
Engagement: Operational Due Diligence
RESULTS
π $4MM annual cost of poor quality identified.
π On-time delivery at 79% flagged, corrective plan launched.
π Forecast accuracy improvement mapped from 60%.
β‘ 97% energy utilization surfaced, prevented wasted automation spend.
π $30 to $35MM capacity growth potential identified post improvement.
CASE STUDY #2
Transforming Customer Service to Unlock $2.5M in Savings and 15:1 ROI
A $350MM consumer products company struggled with seasonal backlogs, poor service levels, and high turnover. OptaProfit partnered to transform customer service and distribution with clear financial and operational wins.
THE CHALLENGE
Two peak seasons underperformed. Customers were at risk. Revenue was at risk. Service teams were decentralized without a clear strategy. Heavy use of temps, weak scheduling, and a growing backlog during peak season made the issues worse.
OUR APPROACH
Assess Current State
Value stream mapping identified $1.6M in savings opportunities.
Daily Problem Solving
Implemented Lean Daily Management and Gemba Walks to surface and resolve issues fast.
Execution Roadmap
Built a kaizen plan to deliver savings and scale capacity up to 6x during peaks.
Targeted Kaizens
Warehouse optimization removed 60k sq. ft. from the footprint, about $500k lease savings.
HR kaizen cut turnover by 50%, about $660k annual savings.
Targeted Kaizens
Offβshored seasonal call center to stabilize coverage and cost.
Improved CRM workflows for a 50% productivity lift.
Recommendations focused on root cause tracking, stronger demand forecasting, daily lean routines, and an energy capacity plan.
CLIENT'S VOICE
βThis transformation gave us the tools and focus we needed to win back customers and prepare for growth. The improvements in both service and savings were beyond expectations.β
Questions about an active deal or a target you are screening? Visit optaprofit.com/consult
CLIENT SNAPSHOT
Industry: Consumer Products
Size: $350MM annual revenue
Situation: Order and issue backlog in peak season, high turnover, decentralized service teams, weak financial performance
RESULTS
π $2.5M hard savings delivered.
β± 50%-90% reduction in aged backlog by product.
β± 30%-50% reduction in preβproduction lead time.
π 50% CRM productivity improvement.
π +35 point gain in employee engagement score.
Questions about an active deal or a target you are screening?
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