Enterprise Client's 45-SKU Expansion with Zero Quality Incidents

This enterprise client had grown rapidly through acquisition, inheriting products from four different contract manufacturers. This created an operational nightmare: inconsistent quality standards, fragmented supply chain, and compliance documentation scattered across systems.

Their quality team spent 60% of their time reconciling batch records and managing supplier audits instead of proactive quality improvement. Two near-miss FDA warning letters in 2024 signaled the urgent need for consolidation.

Additionally, each manufacturer had different MOQ structures and lead times, making inventory planning nearly impossible. The company was carrying $2.3M in excess safety stock just to buffer against supply uncertainty.

Build Your Own Brand executed a 6-month consolidation project to migrate all 45 SKUs to our facility while maintaining continuous supply. We assigned a dedicated project manager and quality liaison to the client's team.

Our facility's unified ERP system eliminated documentation fragmentation—all batch records, stability data, and compliance documents accessible through a single portal. We implemented vendor-managed inventory (VMI) with 4-week rolling forecasts.

For international compliance, our regulatory team managed EU Novel Foods notifications, Health Canada NPN applications, and TGA registrations for their Australian market—reducing the client's regulatory overhead by 80%.

Within 12 months of full consolidation, the client achieved 23% cost reduction through volume consolidation and eliminated $1.5M in excess inventory via vendor-managed inventory.

More importantly, they passed FDA inspection with zero observations—a first in company history. Their quality team now spends 80% of time on proactive improvement rather than supplier management.

The client has since expanded to 52 SKUs and is exploring co-manufacturing arrangements for new market entry in Southeast Asia.