Process Improvement

Companies that create operational excellence consistently outperform competitors, reducing costs while improving quality and accelerating growth. Catalant Experts leverage hands-on Fortune 500 operational experience with top-tier consulting methodologies to:

Identify hidden inefficiencies for sustainable cost savings

Redesign processes for scalable, high-performance operations

Implement continuous improvement frameworks

APPROACH

Transform Operations for Sustainable Excellence

01

Assess current state

Conduct comprehensive analysis through data review, workflow observations, and stakeholder interviews to map existing processes and identify critical pain points and inefficiencies.

02

Define success metrics

Establish clear business goals tied to measurable KPIs, whether targeting cost reduction, faster cycle times, higher quality, or improved customer experience.

03

Identify improvements

Apply root cause analysis, value stream mapping, and performance benchmarking to uncover both quick wins and strategic changes with greatest potential impact.

04

Design targeted solutions

Develop tailored improvements using proven methodologies, prioritizing based on business impact, implementation feasibility, and alignment with strategic goals.

05

Implement with precision

Execute improvements through structured project management, ensuring smooth transitions while managing risks, tracking milestones, and maintaining stakeholder engagement.

06

Sustain improvements

Validate results post-implementation, establish systems for ongoing monitoring, and embed continuous improvement capabilities to create lasting operational excellence.

WINNING TOGETHER

Process Improvement in Action

E-Commerce Operational Transformation
More Success Stories

Problem

A fast-growing E-commerce organization struggled with rising operational costs and fulfillment delays. Manual inventory tracking caused frequent reconciliation errors, while warehouse inefficiencies and outdated workflows created bottlenecks. The lack of real-time visibility and fragmented supply chain hindered scalability and customer satisfaction.

Action

Catalant Experts conducted comprehensive operational assessment within the first week, shadowing key teams and analyzing inventory accuracy, order cycle times, and returns processes. Warehouse layout, SKU placement, and storage utilization were evaluated while identifying immediate improvement opportunities in systems, workflows, and labor allocation.

Results

Delivered transformative operational improvements through strategic execution:

 

  • $1.5M annual cost savings by implementing direct-to-consumer shipping model
  • 52% increase in warehouse operational capacity through layout redesign
  • 46% reduction in backstock inventory, improving space utilization
  • 5-day reduction in average transit times, enhancing customer satisfaction

Utility Billing Accuracy Improvement

A utility billing services provider faced significant invoicing inaccuracies (over $20M in overbilled/underbilled revenues). Catalant Experts documented 40+ Order-to-Cash processes using structured business process mapping standards, identifying 110+ improvement opportunities. The resulting prioritized implementation roadmap enabled the Chief Accounting Officer to systematically address core operational weaknesses and dramatically improve billing accuracy.

New Product Development Pipeline Optimization

A manufacturing company struggled with 80+ unfocused NPD ideas and 20+ diluted projects lacking clear business impact assessment. Implemented a market-driven 4-stage gate process with financial modeling and defined metrics, reducing active projects to under 10 high-probability initiatives. Achieved 4 successful product launches within 6 months and streamlined resource allocation through data-driven prioritization.

FEATURED EXPERTS

Process Improvement Experts

Paul R.

Ex-Oliver Wyman and Alvarez & Marsal process improvement expert

Spearheading enterprise-level transformations through process improvement & redesign via lean/Six Sigma methodologies. 25+ years delivering quantifiable operational impact for energy, utility, industrial and PE portfolio company clients.

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Charlie K.

Operational excellence expert specializing in enterprise-wide lean process improvement

30 years transforming complex operations, utilizing Lean methodologies and data-driven analysis to streamline workflows, improve efficiency, and deliver sustainable process improvements across various industries.

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Wendi W.

Operations executive specializing in industrial and PE portfolio process improvement

Developing market-driven processes across chemicals, manufacturing, and energy sectors for 25+ years. Creates simple yet robust process frameworks that scale with business growth while delivering sustainable operational efficiency and measurable results.

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