Client Overview:
A mid-sized manufacturer of industrial equipment, recognized for quality but challenged by capacity constraints due to growing demand.
The Challenge:
The company had launched a $30 million plant expansion to double production capacity, with a tight 12-month timeline to meet client orders. Halfway through, the project was derailed—equipment installation was behind schedule, local permitting issues had stalled construction, and costs had risen by 35%. The delay threatened $5 million in backlogged orders, and the internal team lacked the bandwidth to regain control.
Our Solution:
Acute PMC embedded a project manager with manufacturing and construction experience as the Interim Expansion Lead. Our hands-on strategy included:
- Permit Resolution: Negotiated with local authorities to fast-track approvals, clearing bottlenecks in two weeks.
- Vendor Coordination: Realigned equipment suppliers and installers with a revised schedule, enforcing penalties for further delays.
- Resource Optimization: Augmented the team with Acute PMC specialists to manage parallel workstreams, from civil engineering to machinery setup.
- Progress Oversight: Used Acute PMC’s proprietary platform to track milestones, mitigate risks, and keep costs in check.
Our leader integrated directly with the plant’s staff, ensuring solutions stuck without halting existing production.
The Results:
- Completed the expansion in 11 months, beating the original deadline.
- Contained cost overruns, saving $4 million from the projected excess.
- Enabled fulfillment of $5 million in backlogged orders, plus $8 million in new contracts.
Why Acute PMC:
While others might have delivered a report and left, Acute PMC provided a relentless leader who drove the project to success on the ground. Our manufacturing project recovery skills turned a potential loss into a growth opportunity.
Client Perspective:
The manufacturer had been at risk of missing critical orders, but Acute PMC’s intervention changed the outcome. One executive said, “We were in over our heads, but Acute PMC stepped in and got us across the finish line ahead of schedule.”
James P., Plant Manager.