Supply Chain Resilience

Today, proactively strengthening supply and manufacturing networks against disruption is essential for competitive advantage. Catalant Experts—former Fortune 500 operators and top-management consultants—use battle-tested frameworks to help organizations:

Identify vulnerabilities in tariffs, shipping, and production

Configure resilient supply chains to withstand geopolitical shocks

Reduce costs while delivering a 15-30% improvement in response capabilities

APPROACH

Build a Resilient Supply Chain that Performs Under Pressure

01

Assess vulnerabilities and risk

Conduct comprehensive risk assessment to identify critical dependencies and failure points. Mapping supplier relationships, logistics nodes, and production constraints creates a detailed vulnerability profile with clear baseline metrics.

02

Define modifiable elements

Identify which elements of the supply chain can be realistically modified—supplier relationships, production locations, component sourcing, or logistics routes. Working with stakeholders, establish consensus on what can and cannot be changed to focus optimization efforts productively.

03

Develop alternative models

Create alternative supply and manufacturing configurations to test against different scenarios. Evaluate the impact of diversifying suppliers, optimizing production networks, and reconfiguring logistics to reduce vulnerability.

04

Build optimization framework

Establish modeling capabilities to test configuration performance under varied conditions. Run sensitivity analyses across factors including tariffs, shipping costs, and exchange rates to minimize total cost variability.

05

Test and select configurations

Execute modeling across all scenarios to identify configurations that minimize total production cost and variance. Select the optimal configuration and test it rigorously under broader challenges to ensure robustness against multiple disruption types.

06

Embed resilience in operations

Institutionalize resilience through standardized protocols and clear accountability structures. Develop contingency playbooks enabling teams to execute predefined response plans when disruptions occur.

WINNING TOGETHER

Supply Chain Resilience in Action

Global Manufacturing Network Optimization
More Success Stories

Problem

A Fortune 50 manufacturer of high-value durable goods operated a sprawling global production network that struggled with high costs, limited flexibility, and increased risk exposure.

Action

Working closely with executives and operational teams, we:

 

  • Established key optimization parameters balancing cost, quality, risk, and flexibility
  • Analyzed product specifications, labor costs, tariffs, exchange rates, and logistics expenses
  • Developed and iteratively tested multiple network configuration scenarios
  • Recommended sweeping changes to product modularity and manufacturing footprint

Results

The reimagined manufacturing network delivered transformative value that:

 

  • Achieved over $100 million in annual operating cost savings
  • Significantly increased network flexibility and responsiveness
  • Established a repeatable methodology now being implemented across other business units

Pharmaceutical Supply Chain Resilience

A $3.8B pharmaceutical manufacturer eliminated frequent stockouts and regulatory compliance risks by implementing a comprehensive resilience strategy. By mapping critical supplier nodes, developing redundancy for previously single-sourced materials, and deploying a digital control tower with AI-driven forecasting, the company reduced stockouts by 35%, improved forecast accuracy by 20%, and cut replenishment cycle times by 15%.

Global CPG Transforms Import Supply Chain

A global beverage leader struggling with high import costs and poor service levels needed help to redesign the import supply chain. The Catalant Expert partnered with cross-functional teams to analyze data, model postponement scenarios, and implement a U.S.-based hub with bulk shipping. The work resulted in a 27% reduction in transportation costs, 30-point jump in OTIF performance, and significantly enhanced regional responsiveness with fewer disruptions.

FEATURED EXPERTS

Featured Supply Chain Resilience Experts

Terry Y.

Ex-PWC, Johnson & Johnson, Merck, ADP, Bristol-Myers Squibb

Supply chain leader implementing multi-sourcing strategies, continuity planning, and digital visibility solutions that deliver regulatory compliance and multimillion-dollar savings for pharmaceutical and biotech networks.

View Profile

Byron W.

Ex-Monitor, John Deere, Cummins, PTC, Ex-fighter pilot, Harvard Ph.D

Global manufacturing strategist guiding multinational operations across Europe, China, and the Americas with proven methodologies for resilient network design and strategic flexibility.

View Profile

Jay J.

Ex-McKinsey expert in resilient supply chain design & optimization

20+ years building resilient supply chains—diagnosing tariff, transport, and production risks; modeling, simulating, and reconfiguring networks for 15–25% faster recovery and 10–20% cost efficiency.

View Profile

Ketul P.

Ex-Deloitte, Michael Kors, ToysRUs, Avon supply chain transformation leader, SCOR-P

Global supply chain strategist connecting sourcing, logistics, and fulfillment to identify risks and design innovative, resilient network solutions that mitigate disruption.

View Profile

Don’t let supply chain vulnerabilities become business disruptions.

Connect with dozens of Experts qualified and ready to do this work.