Service Offering
Supply Chain Resilience
Today, proactively strengthening supply and manufacturing networks against disruption is essential for maintaining a competitive edge. Catalant Consultants—former Fortune 500 operators and top management consultants—use battle-tested frameworks to help organizations:
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 Use Cases
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, the Consultant:
- 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 Consultant 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
Supply Chain Resilience Consultants
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.
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.
Jay J.
Ex-McKinsey consultant 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.
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