Work
/
Business Improvement
A fast-growing FMCG brand was unable to fulfil orders as demand surged past their supply chain capacity. Morgan identified the key constraints, defined a clear target state, and built a phased implementation plan to scale operations and sustain growth.

Industry
Manufacturing
FMCG
Challenge
Unscalable manual supply workflows and warehouse constraints triggering severe retail stockouts mid-growth.
Our Service
Business Improvement & Operations Transformation
Achievements
98.5% order fulfillment rate and 18% operational cost reduction in Year 1.
CONTEXT
A fast-growing FMCG brand was facing increasing growth forecasts, an opportunity to capture market share and rising out of stocks impacting key retail customers
PROBLEM
Out of stocks resulted in lost revenue and not meeting customer KPIs. This jeopardised their relationship with key retailers and put future growth at risk.
This challenge was creating wider pressure across the business:
Uncertainty about business performance
Pressure on senior leadership to deliver growth
Team burnout and higher operating costs from reactive workflows
Strain on supplier relationships
WHAT WE DID
MORGAN assessed business operations to understand key performance metrics, the source of stock outs and what was likely to limit growth in the future. Working with senior leaders, we developed their target operating model and organisational design. Our team reviewed demand and supply planning, growth projections and communicated with co-manufacturers assessed their ability to support future demand. A series of quick-win initiatives were implemented to align key suppliers, establish safety stock targets, and develop risk mitigation activities. This stabilised performance, while the broader transformation was implemented.

THE OUTCOME
Senior leadership gained clarity to make strategic decisions:
They understood which initiatives would unlock growth and which could be deprioritised without impacting business performance. This enabled more effective allocation of limited resources.
Out-of-stock incidents reduced, restoring retailer confidence.
Co-manufacturer leadership gained confidence to invest in long lead time facility upgrades, unlocking additional capacity and support continued growth.
PROOF
10% reduction in stockouts
+$500k revenue per year
>20% capacity unlocked
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