Magnolia Medical was experiencing rapid growth but facing operational strain: backorders, inconsistent fill rates, and margin compression due to manual processes and scaling constraints.
Brought in as Interim Head of Operations to stabilize and scale core systems. Retained as principal consultant for several years after hiring a full-time successor. Led initiatives across automation, cost reduction, fulfillment, and ERP readiness.
· Delivered over $3M in cost savings through product redesign and sourcing strategies
· Implemented automation systems that improved gross margin by 50%
· Improved order fill rate from 60% to 100% via active supplier management
· Assisted in ERP selection and transition prep, positioning the company for scalable growth
Restored fulfillment performance, upgraded manufacturing capability, improved margins and positioned the company for continued expansion with a leaner, more agile ops platform.
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PlenOptika had a deficient prototype of a portable autorefractor in terms of manufacturability, ergonomics, and aesthetics. A complete redesign and a viable manufacturing strategy was needed within a compressed timeline.
Acted as lead operations executive to assess current design, implement corrective action, develop a manufacturing strategy, and establish an efficient, cost-effective supply chain.
· Assembled expert industrial design and mechanical engineering team to redesign the product for manufacturability, aesthetics, and ergonomics
· Selected and onboarded key suppliers and final assembly site with optimal cost and proximity to Madrid-based engineering center
· Supported production ramp-up and initial inventory strategy
Delivered an award-winning,* production-ready product that met cost targets and was built with capital equipment well below budget—enabling launch and revenue generation while preserving working capital..
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The client, developing a personal server, was experiencing sourcing issues and receiving poor service from a Tier 1 contract manufacturer jeopardizing timely product launch. Critical components were difficult to source.
Led operations for the full product launch, resolving sourcing and manufacturing constraints and planning logistics for responsive fulfillment.
· Replaced Tier 1 contract manufacturer with a Tier 3 partner for better alignment with company size, improved responsiveness, and lower cost
· Leveraged industry relationships to secure reliable supply of allocated electronic components
· Designed and implemented logistics and distribution systems for high responsiveness and minimal working capital
Successfully launched the product on time with high quality, reliable supply, and scalable vendor infrastructure, earning recognition by Time Magazine as Product of the Year.*
* https://time.com/collection/best-inventions-2019/5733117/helm-personal-server/
During the early stages of the COVID-19 pandemic, Ventec faced urgent pressure to scale ventilator production dramatically to meet national demand.
Provided strategic and operational support to rapidly expand manufacturing capacity and establish emergency supply chain protocols.
· Helped scale manufacturing capacity by 10x
· Supported emergency sourcing, logistics, and workforce deployment
· Advised on facility layout and process changes to handle volume
Enabled Ventec to fulfill critical government and healthcare orders during the height of the national COVID-19 emergency via quantum-level increase in capacity within a three-month time-frame.
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Spacelabs was struggling operationally with bloated inventory, high labor costs, and inconsistent fulfillment performance.
Engaged to assess the full operations model—from costing and organizational structure to factory execution and cadence—and implement performance improvements.
· Implemented lean workflows and visual floor-level management for multiple product lines
· Rebuilt cost structure with more accurate overhead allocation for better margin visibility
· Introduced KPIs and structured operational reviews with leadership
· Established business rhythm for real-time performance tracking and early issue detection
Improved operational visibility and embedded sustainable management practices. Company divested an unprofitable product line and significantly improved margins.
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