Rapid Operationalization & Change Management
Problem
A global manufacturer leased an additional building to relieve overcrowding in its production facility, where congestion was disrupting operations and delaying the launch of a new micro-fulfillment line designed to improve efficiency. However, despite securing the new space, it remained unused for an extended period. To move forward, the brand needed to rapidly build out and operationalize the facility. This required onboarding a new warehouse vendor, defining and aligning warehouse processes with existing production workflows, and coordinating across both vendors to enable seamless material movement. The effort also involved identifying and relocating stored materials, and implementing new tracking technology to improve visibility, reduce inventory errors, and shorten the lengthy monthly count process.
Approach
Excelerate initially structured the work in two phases—first to establish the new facility and its operating practices, then to transition materials into the space. Early production demands, however, required both phases to be executed simultaneously. The team conducted onsite scoping visits and managed weekly stand-ups to drive progress. Given the underlying tension between the existing and new warehouse vendors, the delivery team facilitated collaborative discussions to align processes, roles, and expectations—enabling a smooth handoff and effective cross-vendor cooperation. Bi-weekly site visits ensured continued progress and accountability throughout.
Results
Excelerate remained adaptive under pressure, successfully executing both project phases in parallel while maintaining stakeholder alignment. Through structured facilitation and clear process definition, the team established a fully functional storage facility and coordinated the materials transfer between sites without disruption. The client’s production schedule stayed on track, the new vendor was set up for success, and both vendors were aligned under a unified operating model.