Global Strategic Sourcing Study

Large Engine Manufacturer

Excellence in Focus

The client achieved annual savings exceeding $25 million (23%), developed a low-cost sourcing strategy in collaboration with an International
Procurement Office (IPO), and enhanced the skill levels of over 150 professionals through extensive training in negotiations, sourcing methodology, executive interviewing, supplier due diligence, and alliance management.

Key Achievements Overview

$ 0 MM+
in verified annual savings
65 %
reduced supply base
> 70 %
on-time delivery metrics

Achieved enhanced pricing stability through proactive commodity pricing management programs.

Secured engineering support for both New Product Development and Product Rationalization initiatives.

Challenge

The client lacked a consistently applied strategic sourcing process, had not explored low-cost sourcing options, faced pricing pressures from competitors, and its workforce lacked the necessary skill sets. Additionally, employees had not received formal training to address future challenges.

Evaluation

The KGM team conducted an in-depth analysis of the client’s supply base, customer requirements, and annual material and service expenditures. Potential savings opportunities were identified, along with technical and organizational issues hindering cost-effective performance. Specifically:

The KGM Team:

  • Conducted interviews with cross-functional teams and facilities management, gathering extensive data to benchmark costs and processes.
  • Identified opportunities to collaborate with global suppliers for operational benefits and cost reductions.
  • Recognized the need for skill-based training and developed a project work plan and timeline to achieve savings.
  • Performed a comprehensive end-to-end supply chain diagnostic to map the current state.
  • Identified suppliers of critical, single-sourced components that imposed unfavorable contract terms and pricing.

Approach

To achieve total cost savings, KGM Strategy implemented a global Strategic Sourcing initiative targeting twelve key categories: Iron & Aluminum Castings, Gears, Electrical Wire Harnesses, Fittings & Hoses, MRO & Production Supplies, Forgings, Machined Components, Fabrications, Fasteners, Oil and Air Filters, and Generators. The KGM team:

  • Gathered and outlined data requirements for analysis.
  • Revised the sourcing department's organizational structure, creating job descriptions and qualifications aligned with industry best practices.
  • Trained client teams in Methodology, Executive Communications, Negotiations, Supplier Due Diligence, and Alliance Management to ensure sustainable improvements.
  • Invested significant time and resources to thoroughly understand the industry and commodities marketplace.
  • Defined commodity-specific negotiable issues for efficient negotiations.
  • Encouraged the client to consider global suppliers rather than relying solely on those within a 150-mile radius by identifying and engaging over 1,200 suppliers worldwide.

Results

Cost savings were achieved by consolidating the client’s supply base and enhancing alliance management. Ongoing cost reductions will be sustained through a new organizational structure, which has increased management awareness of sourcing issues.

  • Realized over $25 million in annual savings from Phase I – 23% savings.
  • Implemented global supply agreements with alternate suppliers, enabling dual-source options for strategic components.
  • Reduced the supply base by 95%.
  • Established consistent processes across all functions.
  • Developed clear metrics to evaluate supplier alliances.
  • Restructured the client’s organization with a focus on professional development and performance measurement.
  • Improved cash flow by extending payment terms by 60–90 days while securing attractive discounts for early payments.
  • Enhanced inventory turns through programs such as consignment, JIT, Kanban, safety stock, local warehousing, and VMI.
  • Negotiated tiered volume rebates.
  • Achieved long-term pricing stability by implementing proactive commodity pricing management programs.
  • Secured commitments for dedicated manufacturing capacity.
  • Achieved On-Time Delivery metrics exceeding 98%.
  • Obtained engineering support for New Product Development and Product Rationalization.

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