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Operating case study

Expand the footprint.
Improve the customer promise.

A private equity backed outdoor furniture manufacturer.

97.6%

Two-day delivery coverage, increased from 40%

Network expansion: 12 months.

The decision the business faced

A single distribution point reached only 40% of customers within two days as demand grew across two brands. Freight costs and transit times were constraining growth. The decision was how to extend delivery reach while keeping inventory, fulfillment, and service standards consistent across a larger footprint.

Decision frame

Alternatives
considered.

  1. Stay with one distribution site and pay for expedited freight. Expedited shipping did not scale with the growth plan.
  2. Outsource regional coverage to 3PLs. This would fragment service standards across providers.
  3. Open regional locations under company control. The business chose a company-controlled network to extend reach while preserving consistent operating standards.
Actions taken

Connect the decision
to the work.

01

Model demand, transit time, and cost

Model demand by region against transit time and cost. Connect the location decisions to the customer promise and the economics of serving demand across two brands, rather than expanding the footprint in isolation.

02

Sequence the regional expansion

Sequence the expansion from one to five company-controlled distribution locations over 12 months. Coordinate the operating footprint with inventory placement and fulfillment workflows so additional locations extended useful delivery reach.

03

Connect routing to carrier strategy

Implement TMS-enabled routing and carrier negotiations. Align transportation workflows and carrier strategy with the expanded network to improve reach while reducing transportation cost.

04

Standardize inventory and fulfillment

Standardize inventory and fulfillment processes across the sites. Connect local execution to a consistent operating model so network growth did not fragment the service standards customers experienced.

Sustainment evidence

What held after
the engagement.

The five-location network and the routing and carrier structure remained in place as the operating footprint. Standardized inventory and fulfillment processes connected those locations into a company-controlled network with broader delivery reach.

Results reflect Warren's prior executive roles and the teams involved.

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