Case Study: Consolidating Multi-Site Operations for Scalable Growth
In 2022, Village Gourmet acquired a new business that required immediate operational integration across existing facilities in Connecticut and Pennsylvania. The leadership team needed to transfer production expertise, protect product quality, maintain customer service levels, and consolidate supply chain operations while minimizing disruption to current customers.
Village Gourmet engaged London Consulting Group to lead the transformation.
Challenge
The acquisition created complexity across production, planning, customer service, warehousing, and distribution. The organization needed a structured approach to transfer product knowledge, optimize capacity, integrate supply chain operations, and redesign the production network.
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 footprint
Redefining distribution routes and partners
Ensuring uninterrupted supply of raw materials and packaging
Onboarding teams to new standards, workflows, and digital tools
Village Gourmet required a fast, efficient, and low-disruption integration approach that improved productivity while preserving long-standing product quality.
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 a larger customer base and expanded product footprint
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 all product clusters, including speed rates, setup times, and changeover expectations
Implemented Daily Scheduling and Production Plan review sessions to manage throughput, adjust capacity, and monitor performance across both facilities
Coordinated equipment transfers and integrated machinery layouts to maximize efficiency in the consolidated network
Supply Chain and Distribution
Redesigned the distribution strategy, introducing cross-docking and new logistics partners
Optimized delivery routes using route modeling software to support a national distribution footprint
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 accommodate new materials and implemented updated inventory management processes, including recurring cycle counts and staff training
Results
The integration achieved the desired goals while protecting ongoing operations and customer satisfaction. Village Gourmet gained:
Faster and clearer knowledge transfer from the acquired operations
Standardized production processes across facilities
Increased efficiency through optimized changeovers, equipment layouts, and daily production control
A more scalable product portfolio
A more efficient and cost-effective distribution network
A fully integrated supply chain and inventory management process
Village Gourmet’s leadership highlighted LCG’s collaborative approach, eagerness to transfer knowledge, and commitment to building internal capability.
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 at Village Gourmet.”
David Kemp
CEO, Village Gourmet