Global Manufacturer Realizes $80M in Productivity Gains Through Process Improvement
An over $20B global company that does light manufacturing and value-added processes struggled to meet the cost as a percentage of sales. Many of the processes were suboptimized and treated as if they were unique. The employees did not feel empowered to offer suggestions or have the appropriate skill set. Services...
Medical Device Manufacturer Achieves US-Based Production at Near-China Costs
A ~$10B global business unit for a Fortune 500 company producing and selling productivity and protective equipment struggled to implement a cost-viable assembly line in the United States (per Customer request) for the medical industry. The processes for manufacturing pressure sensors in the US vs. emerging regions were too disparate,...
Industrial Distributor Cuts Energy Costs by 75% Through Facility Digitization
A $20B+ global business that does light manufacturing and distribution needed to identify a way to reduce costs through digitization of multiple sites. One opportunity is in the utility space, specifically lighting and lighting control. Services Provided Working collaboratively with the client, the team: Replaced old lighting with LED lightingImplemented a mesh network...
Global Fortune 200 Firm Reduces Labor by 78% Through Warehouse Automation
A $20B+ global Fortune 200 company needed to exit a complex warehouse and consolidate it with two other facilities to reduce overhead costs with a centralized operation. The task included relocating outdated carousels for the small parcel operation. The new facility must support a 10% YoY growth and reduce costs. Services...
Distribution Company Achieves 50% Annual Savings Through Supply Chain Optimization
A ~$22B global business providing wire spools cut to size for multiple industries saw a spike in demand in a region. Demand exceeded capacity, creating inventory space issues and cost constraints. Services Provided Working collaboratively with the client, the team: Analyzed the supply chain network and identified the best solution to meet customer...
Fortune 200 Manufacturer Achieves 400% Efficiency Gain Through Automation Consulting
A ~$10B global business unit for a Fortune 200 company producing and selling productivity and protective equipment was unable to meet demand (backlog up 750%, mostly in North America) during COVID-19. The processes for manufacturing masks were very manual and costly. Hiring new operators was difficult, with a high turnover. Services...
Rail Transload Market Strategy: Investment Opportunity Assessment for Global Industrial Leader
A global industrial conglomerate with companies that supply the rail industry needed to evaluate opportunities to enter the US rail transload space. Before pursuing potential investments, the client required a thorough understanding of the market dynamics, key players, and customer requirements to make informed strategic decisions.PLG Consulting conducted a comprehensive...
Optimizing Railcar Planning Through Strategic Market Analysis: How a Global Manufacturer Forecasted Future Demand
A global railcar manufacturer and lessor needed its leadership and sales team to assess demand for all railcar types continuously. Therefore, it engaged PLG to help quantify how changes in the market for renewable fuels and energy transition minerals used to produce electric vehicles would drive future railcar demand.PLG Consulting...
Rail Mode Conversion Analysis for a Leading Specialty Chemicals Producer
A specialty chemicals producer sought expert guidance on converting outbound deliveries from dry van truckload to dry bulk truck/rail via transload. They needed a comprehensive evaluation of the logistics operations and financial viability of this conversion, including an assessment of product handling, facility costs, transportation costs, and capital investment requirements. The project was used to determine...
Terminal Development Strategy: Strategic Market Expansion Analysis
A leading terminal market operator with extensive experience in rail terminal development and operationsidentified an opportunity to expand their portfolio through new terminal development at a strategic coastal location. The client needed a comprehensive assessment of various commodity opportunities to determine the optimal use of their potential terminal properties. This strategic evaluation would help...
Private Equity Success: Evaluating a Logistics Service Provider for Strategic Investment
A leading private equity firm needed to evaluate a potential investment in a specialized logistics services provider that operates within chemical plants and oil refineries. Before bidding, the client needed to understand detailed aspects of the business that were largely opaque because they occur within the confines of the industrial...
Rail Infrastructure Expansion for a Leading Electric Vehicle Manufacturer: Lithium Processing Engineering and Design
A leading electric vehicle manufacturer sought to expand its lithium processing capabilities to meet the growing demand for battery components. To this end, the company was developing rail infrastructure at its new lithium processing facility. The goal was to design an efficient track layout to handle inbound raw materials and outbound finished products while optimizing...
