Key results from the engagement
Where it started
Alderbrook had grown rapidly across multiple facilities, but its operational processes had not kept pace. Manual workflows, inconsistent reporting, and duplicated tasks were creating delays across key functions, while rising operating costs were putting pressure on margins.
The leadership team initially considered adding more resources to handle the growing workload. We suspected the real constraint was operational efficiency, not capacity — and the numbers backed that up.
What we did
We began with a full operational diagnostic — mapping core workflows, resource allocation, process bottlenecks, and performance metrics across the business. That analysis highlighted several areas where manual steps and fragmented processes were slowing execution and increasing costs.
In parallel, we identified $1.3M in operational inefficiencies — primarily from duplicated workflows, underutilized resources, and inconsistent processes — and built a streamlined operating model focused on automation, accountability, and measurable performance improvement.
What changed
The operational improvements reduced production bottlenecks and improved throughput across the facility, while standardized workflows brought greater consistency to day-to-day operations. Combined with tighter inventory controls, operating margin improved from 11.4% to 19.6% over the engagement.
Efficiency gains that created lasting impact
The redesigned operating model reduced process inefficiencies and improved resource utilization across key production areas. Combined with workflow standardization and inventory optimization, EBITDA margin moved from 11.4% to 19.6% by the close of the engagement.