Global Manufacturing Division Reduces Costs and Builds Sustainable Supply Chain Playbook Across Three Continents

Situation

A global manufacturing leader faced intense market competition and rising demand during the soft coal and commodity mining boom. The company’s manufacturing footprint lacked the capacity and capability to meet demand. Outdated equipment, heavy outsourcing, and high supplier costs drove rising manufacturing costs and inconsistent delivery performance.

Actions

MetaExpert Robert was brought in as Product Supply Integration Leader, covering both manufacturing and external supply chains. He launched a Lean Six Sigma project spanning:

  • $600M in cost of goods sold and more than 4,500 SKUs
  • Operations across the U.S., Europe, and Australia

Using the DMAIC process, Robert and his team:

  • Distinguished core vs. non-core manufacturing to focus investments wisely
  • Conducted make vs. buy analyses to determine cost-effective sourcing
  • Developed a capital equipment roadmap for long-term internal capacity
  • Built a strategic sourcing roadmap for external suppliers
  • Created sustainable playbooks for sourcing, make/buy, and R&D integration

Results

The initiative delivered measurable impact:

  • Achieved targeted financial performance improvements in cost and profitability
  • Strengthened supplier relationship management practices
  • Implemented ongoing strategic sourcing playbooks still in use today
  • Standardized make vs. buy decisions across multiple divisions
  • Shared as a best practice model across the enterprise

Return on Investment

  • $600M in cost base analyzed
  • Cost and delivery performance stabilized across three continents
  • Established long-term savings and capacity improvements
  • ROI amplified by sustainable playbooks enabling continuous cost savings and process improvements beyond the project
Lean Six Sigma roadmap drove $600M supply chain transformation across three continents.

Conclusion

By applying Lean Six Sigma discipline and aligning sourcing with manufacturing strategy, Robert helped the company stabilize costs, improve delivery, and build sustainable practices. His work not only solved immediate capacity constraints but also left behind scalable systems that continue to drive performance today.

Project Details

  • Industry: Complex Manufacturing
  • Role: Product Supply Integration Leader
  • Duration: 3–4 months, full-time
  • Skills Applied: Lean Six Sigma, Strategic Sourcing, Supply Chain Integration, Cost Optimization, R&D alignment