NorthForge works with executives running complex, multi-site distribution and manufacturing networks — installing the performance systems, leadership cadence, and accountability structures that turn strategy into disciplined daily execution. Built by an operator who has cleared $35M backlogs, quadrupled capacity, and set global performance records inside real operations.
The difference between a recommendation and a result is the system that survives after the consultant leaves. That system is the deliverable.
Fifteen-plus years accountable for the P&L reality of multi-site operations — 250+ person teams, million-square-foot footprints, $20M+ budgets, from industrial distribution to GMP-regulated pharmaceutical manufacturing. Every framework offered here has been run live, under pressure, with real consequences.
Performance systems designed to hold up inside collective agreements — grievance-defensible, seniority-aware, and built with the floor rather than against it. This is rare in consulting, and decisive in practice.
Every engagement is anchored to metrics that existed before we arrived and improve after we leave: fill rate, turnaround time, cost per unit, backlog age. If it can't be measured, it isn't claimed.
No open-ended retainers. The engagement ends when your leaders run the system without us — dashboards live, cadence installed, capability transferred. The track record: 6 Green Belts and 30+ Yellow Belts certified inside frontline operations. Dependency is a consulting business model. It isn't ours.
Every engagement leaves behind working infrastructure your teams run themselves — measured, standardized, and built to survive leadership turnover, peak season, and growth.
KPI engines, executive dashboards, and tiered accountability structures that make targets visible, drift impossible to ignore, and performance conversations factual instead of anecdotal.
Standardized work, training matrices, and repeatable processes that align facilities across borders — so a model proven at one site scales cleanly to the next, in any labor environment.
Kaizen discipline, root-cause problem solving, and Belt-level capability built into frontline operations — paired with automation, AI-assisted analytics, and digital tooling that compounds the gains.
Every engagement is scoped to a measurable outcome and structured to make NorthForge unnecessary — because the system we leave behind is yours.
On-the-floor assessment of your operation: flow, data, leadership cadence, and where performance actually breaks. You receive a prioritized findings report with quantified opportunity — not a generic maturity model.
The blueprint: KPI architecture, standard work, accountability structure, and automation roadmap — engineered for your sites, your systems, and your labor environment, with ROI attached to each move.
Hands-on implementation alongside your leaders — building the dashboards, running the tier meetings, coaching the cadence — until the system runs without us and the results are visible on the floor.
Led multi-site operations spanning nearly 1M sq. ft. within a ~$1B regional business — scaling engineered assembly 4× in 18 months and delivering $1M+ in annualized savings across 26 continuous-improvement initiatives.
Cleared a $35M past-due order backlog to zero aged orders, cut operations-related customer complaints by 75%, and lifted picking efficiency 30% — while raising employee engagement scores from 3.2 to 3.99 out of 5. Performance and morale rose together, because the system was built with the floor.
Directed 500,000+ sq. ft. of distribution with a 250-person unionized team — improving fulfillment turnaround 56% while shipping 15M+ units annually, with $1M+ per year in variable cost savings two years running.
Named the best-performing distribution center worldwide within a multinational network — implementing voice automation to reach a record 99.992% fill rate and absorbing five consecutive years of sales growth with zero added headcount. Three-time best-site honoree, plus 13 best-DC-of-the-quarter awards.
Held P&L for distribution networks spanning the U.S. and Canada — lifting EBITDA 20% in a single year through process standardization, contract renegotiation, and overtime elimination, then boosting productivity 8% across five DCs with a $20M operating budget.
Drove inventory accuracy from 69% to 100% on $18M of inventory in a regulated pharma environment — delivering a 14-month SAP WMS implementation on schedule and leading warehouse operations through successful Health Canada and FDA audit preparation.
"Performance does not improve through intention. It improves through structure."
NorthForge Strategy is led by a senior operations executive with 15+ years directing large-scale, multi-site distribution, manufacturing, and supply-chain operations across North America — spanning industrial distribution, engineered assembly, automotive, and GMP-regulated pharmaceutical environments, in union and non-union workforces, through high growth, turnaround, and transformation.
That experience spans Lean deployment, warehouse automation, and WMS/ERP modernization, backed by an Executive MBA, a Lean Six Sigma Black Belt, and selection as one of six global finalists for an enterprise Lean Leadership award within a multinational organization.
This is not theoretical consulting. It is structured execution discipline forged inside real operations — under pressure, at scale, and measured by the numbers that show up on the floor.
If you are building, stabilizing, or scaling multi-site operations and want systems that hold under pressure — the first conversation is direct, confidential, and worth your time.