Case Study: Consolidating Multi-Site Operations for Scalable Growth
A multi-brand specialty food platform with five SQF-certified facilities sought to integrate a newly acquired business into its national operations. With a diverse portfolio spanning premium meats, charcuterie, and snacking products, the company operates in a high-complexity environment that requires tight coordination across production, planning, customer service, and supply chain.
To maintain artisanal quality while scaling a multi-site network, the leadership team needed to transfer product knowledge, unify workflows, protect product standards, and ensure seamless customer service throughout the integration.
The organization engaged London Consulting Group to lead the transformation.
Challenge
The acquisition introduced significant complexity across production, planning, customer service, warehousing, and distribution. The company needed a structured approach to consolidate operations across facilities, optimize capacity, unify production processes, and fully integrate the supply chain.
Key challenges included:
Transferring recipes, machinery setups, and handcrafted production processes across facilities
Consolidating and rationalizing an expanded product portfolio
Managing a larger customer service and order management footprint
Redefining distribution routes and logistics partners
Ensuring uninterrupted supply of raw materials and packaging
Onboarding teams to new standards, workflows, and digital tools
The organization required a fast, efficient, and low-disruption integration approach that improved productivity while preserving the product authenticity its brands are known for.
Approach
London Consulting Group deployed a sprint-based methodology focused on knowledge transfer, operational standardization, supply chain redesign, and real-time performance management.
Sales and Customer Service
Consolidated and rationalized the product portfolio by 40 percent with minimal impact on revenue
Redesigned calling plans and service models to support expanded customer and product coverage
Production Integration
Documented and transferred all recipes, equipment setups, operational instructions, and handcrafted techniques using spec sheets, production binders, QC documentation, and training videos
Defined updated operational standards for product clusters, including speed rates, setup times, and changeover expectations
Implemented Daily Scheduling and Production Plan review sessions to manage throughput, balance capacity, and monitor performance across facilities
Coordinated equipment transfers and integrated machinery layouts to maximize efficiency across the consolidated network
Supply Chain and Distribution
Redesigned the distribution strategy, introducing cross-docking and updated logistics partners
Optimized delivery routes using route modeling software to support national distribution
Integrated raw material and packaging supply chains using a mix of existing and new vendors to reduce cost and improve lead time
Reorganized warehouse layouts to support new materials and implemented updated inventory management processes, including recurring cycle counts and staff training
Results
The integration achieved its targeted goals while maintaining service levels and protecting product quality. Key outcomes included:
Faster and clearer knowledge transfer across sites
Standardized production processes and operational expectations
Increased efficiency through optimized changeovers, equipment layouts, and daily control systems
A more scalable and balanced product portfolio
A more efficient and cost-effective distribution network
A fully integrated supply chain and improved inventory management
Leadership highlighted LCG’s collaborative approach, commitment to capability building, and structured methodology that accelerated the integration while strengthening long-term performance.
Client Testimonial
“London Consulting Group helped us achieve the goals of our project. The consulting team used a sprint methodology and was eager to help and transfer knowledge to our team. We recommend LCG to any company in similar projects involving manufacturing process improvements, implementation of digital tools, and change management. We will happily partner with LCG in future projects.”
— CEO, National Specialty Food Manufacturer