Notable Project Achievements
We work with companies of all sizes, including several of the Fortune 50 as well as many mid- and small-cap companies. Our projects include questions of strategy, tactics and operations. Regardless of the size or scope of the question, Caplan has an established record of delivering significant cost avoidance, productivity improvements and other savings.
$1 million in cost avoidance
The $4 billion division of a Fortune 50 client hired Caplan to design a new distribution center to support several of its manufacturing plants. Caplan was responsible for determining the size, layout, storage methods (floor, rack, automated), number of docks, and other aspects of the Greenfield site. After more than 2 years on the “potential projects” list, this New Site was funded after we identified $1 million in cost savings opportunities versus the company’s previous estimates.
5-year Site Master Plan incorporating a new Distribution Center
This $25+ million project involved integrating a new distribution center with an existing plant in the Philippines. Caplan was responsible for developing options for the DC site layout (internal and external) and designing external traffic flows for the combined operation.
$0.5MM in annual savings; $3MM in capital avoidance; $5MM in additional asset disposal opportunities.
This $20+ million project involved the retro-fit of an entire manufacturing plant. Scope included site-clearing an existing business (along with its support services), expanding a second business, and adding a third business to the site. In addition, the site was undertaking a broad employee re-organization project. Our solution incorporated scope, cost, and phasing as well as an analysis on the effect of plant layout on various organizational structures (technology-focus, brand-focus, etc…)
10-year Site Master Plan
This $150+ million project included the front-end planning for a new production module and distribution center at an existing site in Brazil. Caplan’s involvement included project team facilitation, option development, facilities planning and logistics support.
$5 million in annual savings & a 30% ROIC
This project involved 4 manufacturing plants and a supply contract worth $150+ million per year. Caplan was responsible for conducting the due diligence on the target sites. In addition, we used custom financial and operational models to develop a combined supply chain strategy and transfer pricing on the supply contract.
