The Challenge

For modern brands, products often require final configuration, customized kitting, or light assembly before they can ship. Fragmenting these steps across multiple vendors or delaying them until the warehouse floor introduces massive risks: quality control issues, significant lead time increases, and inflated labor costs. Businesses need a seamless, profitable solution that brings manufacturing closer to the customer.

Integrated Value, Maximized Margins

I specialize in integrating value-added services (VAS) directly into the core fulfillment process, turning the warehouse into a responsive, high-accuracy light manufacturing and customization hub. My expertise is in defining the scope, setting profitable pricing models, and executing the processes required to expand service offerings for both internal and 3PL/4PL operations.

Strategic Service Expansion & Monetization

I have a proven track record of identifying and launching profitable adjacent services that drive new revenue streams and increase client stickiness.

• New Revenue Streams: Successfully expanded services to include light manufacturing, assembly, and call center capabilities, contributing directly to a startup's growth and achieving profit margins between 11.1% and 20.3% over nine years.

• Scope Management: Designed and managed operations that encompassed warehousing, fulfillment, call center, and assembly capabilities across a 3PL/4PL network totaling over 3 million square feet.

Process Excellence in Assembly & Kitting

Value-added services must maintain the highest standards of quality and efficiency. I leverage certified methodologies to ensure excellence.

• Accuracy: Applied Lean Six Sigma Black Belt (LSSBB) expertise to engineer assembly and kitting processes that maintain a 99.98% order accuracy benchmark, ensuring customized products ship correctly the first time.

• Industrial Engineering: Experience in facility layout and design, ensuring kitting and assembly stations are strategically placed to eliminate unnecessary material movement and optimize labor flow.

Turnkey Client Solutions

My experience covers the entire integration lifecycle, from initial client onboarding to ongoing quality control and P&L management.

• End-to-End Control: Provided consulting on facility layout and design, including racking systems, order flow, and labor planning, specifically to support retail order fulfillment and value-add preparation.

• Executive Oversight: Managed and budgeted P&L statements up to $500 Million, ensuring the VAS division contributes positively to overall EBITDA targets.

Core Value-Add Capabilities

• Custom Kitting: High-volume assembly of pre-packs, seasonal displays, and customized subscription boxes.

• Light Manufacturing & Assembly: Integrating final product configuration, quality checks, and component joining into the fulfillment flow.

• Inventory Preparation: Expert processes for special labeling, ticketing, and compliance-based inventory preparation (e.g., Hazmat, USDA).

• Reverse Logistics & Refurbishment: Designing systems to efficiently manage returns that require inspection, light repair, or repackaging for resale.

If you need to profitably expand your logistics services, reduce costs through integrated kitting, or leverage value-added services for strategic growth, let's discuss how I can implement an efficient, high-accuracy program.

View my detailed project portfolio or schedule a strategic consultation today.