Impacting Private Equity Holdings


How Flow Consulting
Impacts Private Equity Holdings
What Sets Flow Consulting Apart
Flow Consulting uses a distinctive model to bring talent and
   insight to client engagements
! Experience
    
    All of our consultants have deep business and management experience
!  Data-Based Analytical Approach
       Our assessments leverage data to objectively identify opportunities for cost
        savings and upsides
! Partnership – We work as team members with our clients
   
       We teach client associates to gather initial data to make us cost effective
       We facilitate and partner in planning (e.g., kaizens) but ensure the client
        owns solutions and implements to achieve results
       We work with our clients as necessary to ensure they achieve the expected
        results
! Knowledge Transfer – We transfer knowledge and skills to our clients
   
  to help them become as self sufficient as they desire to be



                                          2
Investment Based Clients
Riverside Company (Exclusive ‘Toolkit’ Provider)
Hampshire Equity Partners
Odyssey Investment Partners

Ulysses Management
Founder’s Equity

Citic Provident

Icahn Holdings
Dogwood Equity

Cortec
Century Park

Wincove

                                    3
Experiences with The Riverside Company – Page 1
Experient – Conference Services Company
! I ntegration of three companies into one
GreenLine – Fresh Green Bean and Herb Thyme Packaging and Sales
! Site consolidation and operational improvement
   
Richter – Pumps and Valves
! Due diligence and post close activity
   
Vokes Air – Industrial Air Filters
! Operational improvement and mentoring
   
Moss – Large Display Solutions for Trade Shows
! Business process analysis with focus on cycle time
   
WaterJel – Medical Burn Solutions
! Lean Manufacturing Assessment
   
Eemax– Instantaneous Hot Water Heaters
! Due diligence and operational improvement
   
                                                   4
Experiences with Riverside – Page 2
Diatron – Medical Testing Devices - Hungary
 !  New product introduction cycle time
Veritext – Legal Deposition Scheduling and Reproduction
 !  Site consolidation analysis and recommendations
Thibaut – High End Wall Paper Manufacturer and Distributor
 !  Inventory reduction analysis and recommendations
Monesson Hearth – Fireplace and Woodstove Manufacturer
! Facility and business integration
   
Polar Windows – Weather Resistant Door and Window Manufacturer - Canada
! Operational improvement
   
KeyCast – Metal Castings
! Operational improvement
   
Sigg – Metal Water Bottle Manufacturer - Switzerland
! Operational improvement
   
                                                  5
Additional Clients
Cameron – Oil Field Drilling Equipment

Gulf States Toyota Distribution – Five State Regional New
Car Distributor

SPX – Industrial Products

Lockheed Martin - Aerospace

Nokia - Telecom

SCJohnson – Consumer Goods

Unilever – Consumer Goods

Syncrude – Oil Recovery from Tar Sands
                              6
Defining the Way We Work
Discovery – from the first visit to taking ownership
!  Snapshot – during the first visit, develop our perspective on the
  potential issues and opportunities within operations
!  Due diligence – developing the next level of issues and opportunities
   in the following areas

Diagnosis – Understanding the issues and opportunities
! Performed in an ‘operational baseline’ with key leaders in the business
    
!  Ownership is transferred from Flow to the leadership team
!  Develop the agreed upon priorities, timing, and ownership for an
   operational strategic plan for the next 18 months

Delivery – Assisting the leadership team in delivering the
  operational plan
! Transition from a high support role to a reduced role over
   
   18 months                         7
Operations Assessment During Due Diligence
First look, first visit, the ‘30,000 ft view’, our Snapshot
!  Inventory levels – is inventory too high, is there an aging issue
!  Labor levels – are there opportunities to significantly reduce using
  Lean Six Sigma tools
!  Supply chain – are their apparent logistics savings opportunities, is the
   materials acquisition department being run professionally and
   strategically
! Capacity and capital investment issues – can apparent capital needs be
   
   deferred using lean tools and product flow improvements, is more floor
   space really needed, or can the total footprint be reduced
! Operating systems – is it stable, is it helpful, does it need to be replaced
    
!  Operational stability – is there chaos, is there a large past due backlog,
   are there significant customer quality issues, is the product flowing
   smoothly
                    Surface obvious issues, and
                      surface obvious upside
                                  8
Next Step – More Detailed Discovery- Inventory
Is there too much – raw, WIP, and finished goods, and why

Is there an aging issue – is it building, and why

Diligently locate ALL storage, ALL warehouses, ALL
  inventory (nearly 100% of the time extra space has been
  found AFTER the deal) – get all leases and get all owned or
  leased property documented




                                9
Labor
Perform random work sampling – estimate percentages of
  wasted time – movement, transportation, walking,
  searching, waiting, reworking, sorting – not adding value

Can labor be separated by product categories to understand
  product profitability after ownership

What is the turnover rate, absentee rate

Are there critical work force elements, especially tied to the
  bottlenecks, nearing retirement




                                10
Supply Chain – Purchasing Focus
Is there professional well trained leadership responsible for
   sourcing the materials needed to feed to product lines

Get a pareto chart of spend by supplier

Understand the significance of any single source issues

Is there benefit in a ‘low cost country’ sourcing aspect that is
   not being considered

Is there kanban linkage to the floor on key high volume items

Is there too much effort being extended in PO documentation
   versus long term agreements

Are there any supplier contracts and commitments for key
  materials and components 11
Supply Chain – Logistics Focus
Has there been a third party professional analysis done on the
  costs of logistics support

What are their logistics costs compared to industry
 benchmarks

Is their logistics leader well trained and up to date on the latest
   trends




                                12
Capacity and Capital Investment Issues
Find the bottleneck(s) – observe the bottleneck and work to
  gain information on operating percentages, shifts worked,
  maintenance program, quality output

Study the work space – is there wasted areas, is there a lot of
  walking, is there storage of noncritical support items or
  files, illustrate with digital photos

Is there an effective well run preventive maintenance program
   in place. If not, are key pieces of equipment at peril for
   imminent replacement




                                13
Operating Systems
What is the system, is it up to date, is it helpful, does it have
 reports that help to manage the operations

Will the system need to be replaced or significantly enhanced
 within the next 3-5 years

If multiple sites, are they all on the same system and are the
   connections seamless

How easy is it to get data or reports, can users get data or only
  the IT guy




                                 14
Operational Stability – Lack of Chaos
!    
    Is the operations manager a professional well trained and open minded leader
!    
    Are there process improvement personnel that are well trained and open
    minded for improvements
!    
    Is there an S&OP (sales and operations planning) process linked to operations
    capacity and sales trends
!    
    Are schedules clear, and are the schedules held
!    
    Are the schedules clearly communicated or are the schedules central to one key
    person
!    
    Are the schedules where they need to be on the operations floor and highly
    visible
!    
    Is there a daily detailed scheduled meeting and a weekly higher level schedule
    meeting
!    
    Are there too many ‘production control’ and scheduling / move expediting
    personnel on the shop floor
!    
    Is there an effective root cause and corrective action process leading to
    continued improvement of quality – operations, logistics, sourced product,
    warranties, etc. Is there a professional quality manager
                                        15
Outputs and Next Steps – the Deeper Dive
Outputs
!  Key issues/concerns that needed to be factored into the potential
  purchase of the company
!  Upside potential ranges that may help in a competitive bidding process
The outputs may surface the need for a Deep Dive in one or
  more of the operational areas?
! Narrow the range of the estimated upside
    
!  Better understand the risks



                                   16
Diagnosis - If the Acquisition Proceeds Past Due Diligence
Prior to close:
! Estimate the consulting effort and the subsequent return on that effort
    
!  Set the consulting effort aside as a reserve for the leadership team
!  Give the new leadership team goals and incentives tied to the
   improvement objectives identified

Just after close:
!  Work with management to develop the 12-24 month operating strategy
  and plan to reach the identified goals
!  Set the consulting budget and schedule
! Plan the level of transfer of knowledge needed after the consultants
    
   finish



                                    17
Delivery – Focus on the First 18 Months
Agree upon the action plan that focuses on the highest
  priorities
! I mpact to EBITDA
!  Impact to customer delivery issues and quality
!  Impact on inventory to free up cash
Typically run 2-4 kaizens while coaching and training the
  internal leadership to ‘fish’ themselves

Activity tapers from leading the kaizens to coaching the
  internal team to run the kaizens

Many clients end with training programs on critical lean and
 six sigma tools that are most applicable to their business

                                   18
Reese Bourgeois



reesebourgeois@flowconsulting.com
386.208.6146
www.flowconsulting.com


                                                          Tell me and I forget; Teach me and I remember; Involve me and I learn.
                                                          - Ben Franklin




 CONFIDENTIALITY NOTICE: The contents of this document including all words, graphics, and other materials contained herein are the
 exclusive confidential and proprietary property of Flow Consulting, Inc. No portion of the enclosed may be copied, reproduced, transmitted,
 disseminated, or used in any manner without first obtaining the written permission of Flow Consulting, Inc. Live Oak, Fl, USA.
Case Study Background
New York Based Private Equity Firm
Had Signed Letter of Intent – Truck and Fire Engine
Equipment Manufacturer
Board Member and Existing Client Recommended Flow
Consulting to Study Operational Opportunities
Four Day Intensive Assessment Revealed the Following:
! was 50% of their business in cycle time on largest product line, which
    Potential for 75% reduction
!  Potential for 40% increase in labor effectiveness on largest product line
! which theto increase capacity by at least 50%withoutneed and mortar,
     
    Potential
               newly acquired company stated as a dire
                                                          brick

! Opportunity to reduce costs by at least 15% on 40% of their purchased
     
  commodities through strategic sourcing

                                     20
Results
First Project – data collection and 2 kaizens
!  Increased capacity in largest production from 65 units/shift to over 90
  units/shift with a reduction of 2 employees
!  Manufacturing cycle was reduced from 5 days to 4 hours
! The hourly crew was able to devote an hour nearly every day to
    
   continuously improve by implementing the 150 action items identified
   in the 2 kaizens

Second Project – data collection and 1 kaizen
!  Increased capacity on second largest production line by 33% on one
  product and 20% on second product
!  They accomplished this with the same number of employees
! Manufacturing cycle decreased from 1 day to 2 hours
    
! I nternal operations team performed at least half of the kaizen
   facilitation                     21
Results
Purchasing Initiative
!  Lean procurement was implemented with 10% price targets for over
  40% of the purchases
!  Increased payables from 10 days to 30 days to free up $600k in cash
! Trained all purchasing personnel and engineering personnel in
    
   negotiations training and vendor contact controls

Training
! Trained all operations, finance, purchasing and material control
   
   personal in Lean Sigma tools
! Trained one process engineer to Black Belt status in Lean Sigma
    
!  Sold licensing fee for perpetual usage of Flow Consulting Lean Sigma
   training materials


                                    22
In Conclusion
Within two years:
! Profitability increased by 20%
    
!  Hourly productivity ultimately improved by 40%
Our client exited earlier than their targeted three year cycle,
but:

              $9 million investment by our client
              turned into $30 million in less than
              three years. Client grew sales while
                 we added nearly free capacity




                                 23

2009 Flow Impacting Private Equity

  • 1.
    Impacting Private EquityHoldings How Flow Consulting Impacts Private Equity Holdings
  • 2.
    What Sets FlowConsulting Apart Flow Consulting uses a distinctive model to bring talent and insight to client engagements ! Experience    All of our consultants have deep business and management experience !  Data-Based Analytical Approach   Our assessments leverage data to objectively identify opportunities for cost savings and upsides ! Partnership – We work as team members with our clients     We teach client associates to gather initial data to make us cost effective   We facilitate and partner in planning (e.g., kaizens) but ensure the client owns solutions and implements to achieve results   We work with our clients as necessary to ensure they achieve the expected results ! Knowledge Transfer – We transfer knowledge and skills to our clients   to help them become as self sufficient as they desire to be 2
  • 3.
    Investment Based Clients RiversideCompany (Exclusive ‘Toolkit’ Provider) Hampshire Equity Partners Odyssey Investment Partners Ulysses Management Founder’s Equity Citic Provident Icahn Holdings Dogwood Equity Cortec Century Park Wincove 3
  • 4.
    Experiences with TheRiverside Company – Page 1 Experient – Conference Services Company ! I ntegration of three companies into one GreenLine – Fresh Green Bean and Herb Thyme Packaging and Sales ! Site consolidation and operational improvement   Richter – Pumps and Valves ! Due diligence and post close activity   Vokes Air – Industrial Air Filters ! Operational improvement and mentoring   Moss – Large Display Solutions for Trade Shows ! Business process analysis with focus on cycle time   WaterJel – Medical Burn Solutions ! Lean Manufacturing Assessment   Eemax– Instantaneous Hot Water Heaters ! Due diligence and operational improvement   4
  • 5.
    Experiences with Riverside– Page 2 Diatron – Medical Testing Devices - Hungary !  New product introduction cycle time Veritext – Legal Deposition Scheduling and Reproduction !  Site consolidation analysis and recommendations Thibaut – High End Wall Paper Manufacturer and Distributor !  Inventory reduction analysis and recommendations Monesson Hearth – Fireplace and Woodstove Manufacturer ! Facility and business integration   Polar Windows – Weather Resistant Door and Window Manufacturer - Canada ! Operational improvement   KeyCast – Metal Castings ! Operational improvement   Sigg – Metal Water Bottle Manufacturer - Switzerland ! Operational improvement   5
  • 6.
    Additional Clients Cameron –Oil Field Drilling Equipment Gulf States Toyota Distribution – Five State Regional New Car Distributor SPX – Industrial Products Lockheed Martin - Aerospace Nokia - Telecom SCJohnson – Consumer Goods Unilever – Consumer Goods Syncrude – Oil Recovery from Tar Sands 6
  • 7.
    Defining the WayWe Work Discovery – from the first visit to taking ownership !  Snapshot – during the first visit, develop our perspective on the potential issues and opportunities within operations !  Due diligence – developing the next level of issues and opportunities in the following areas Diagnosis – Understanding the issues and opportunities ! Performed in an ‘operational baseline’ with key leaders in the business   !  Ownership is transferred from Flow to the leadership team !  Develop the agreed upon priorities, timing, and ownership for an operational strategic plan for the next 18 months Delivery – Assisting the leadership team in delivering the operational plan ! Transition from a high support role to a reduced role over   18 months 7
  • 8.
    Operations Assessment DuringDue Diligence First look, first visit, the ‘30,000 ft view’, our Snapshot !  Inventory levels – is inventory too high, is there an aging issue !  Labor levels – are there opportunities to significantly reduce using Lean Six Sigma tools !  Supply chain – are their apparent logistics savings opportunities, is the materials acquisition department being run professionally and strategically ! Capacity and capital investment issues – can apparent capital needs be   deferred using lean tools and product flow improvements, is more floor space really needed, or can the total footprint be reduced ! Operating systems – is it stable, is it helpful, does it need to be replaced   !  Operational stability – is there chaos, is there a large past due backlog, are there significant customer quality issues, is the product flowing smoothly Surface obvious issues, and surface obvious upside 8
  • 9.
    Next Step –More Detailed Discovery- Inventory Is there too much – raw, WIP, and finished goods, and why Is there an aging issue – is it building, and why Diligently locate ALL storage, ALL warehouses, ALL inventory (nearly 100% of the time extra space has been found AFTER the deal) – get all leases and get all owned or leased property documented 9
  • 10.
    Labor Perform random worksampling – estimate percentages of wasted time – movement, transportation, walking, searching, waiting, reworking, sorting – not adding value Can labor be separated by product categories to understand product profitability after ownership What is the turnover rate, absentee rate Are there critical work force elements, especially tied to the bottlenecks, nearing retirement 10
  • 11.
    Supply Chain –Purchasing Focus Is there professional well trained leadership responsible for sourcing the materials needed to feed to product lines Get a pareto chart of spend by supplier Understand the significance of any single source issues Is there benefit in a ‘low cost country’ sourcing aspect that is not being considered Is there kanban linkage to the floor on key high volume items Is there too much effort being extended in PO documentation versus long term agreements Are there any supplier contracts and commitments for key materials and components 11
  • 12.
    Supply Chain –Logistics Focus Has there been a third party professional analysis done on the costs of logistics support What are their logistics costs compared to industry benchmarks Is their logistics leader well trained and up to date on the latest trends 12
  • 13.
    Capacity and CapitalInvestment Issues Find the bottleneck(s) – observe the bottleneck and work to gain information on operating percentages, shifts worked, maintenance program, quality output Study the work space – is there wasted areas, is there a lot of walking, is there storage of noncritical support items or files, illustrate with digital photos Is there an effective well run preventive maintenance program in place. If not, are key pieces of equipment at peril for imminent replacement 13
  • 14.
    Operating Systems What isthe system, is it up to date, is it helpful, does it have reports that help to manage the operations Will the system need to be replaced or significantly enhanced within the next 3-5 years If multiple sites, are they all on the same system and are the connections seamless How easy is it to get data or reports, can users get data or only the IT guy 14
  • 15.
    Operational Stability –Lack of Chaos !   Is the operations manager a professional well trained and open minded leader !   Are there process improvement personnel that are well trained and open minded for improvements !   Is there an S&OP (sales and operations planning) process linked to operations capacity and sales trends !   Are schedules clear, and are the schedules held !   Are the schedules clearly communicated or are the schedules central to one key person !   Are the schedules where they need to be on the operations floor and highly visible !   Is there a daily detailed scheduled meeting and a weekly higher level schedule meeting !   Are there too many ‘production control’ and scheduling / move expediting personnel on the shop floor !   Is there an effective root cause and corrective action process leading to continued improvement of quality – operations, logistics, sourced product, warranties, etc. Is there a professional quality manager 15
  • 16.
    Outputs and NextSteps – the Deeper Dive Outputs !  Key issues/concerns that needed to be factored into the potential purchase of the company !  Upside potential ranges that may help in a competitive bidding process The outputs may surface the need for a Deep Dive in one or more of the operational areas? ! Narrow the range of the estimated upside   !  Better understand the risks 16
  • 17.
    Diagnosis - Ifthe Acquisition Proceeds Past Due Diligence Prior to close: ! Estimate the consulting effort and the subsequent return on that effort   !  Set the consulting effort aside as a reserve for the leadership team !  Give the new leadership team goals and incentives tied to the improvement objectives identified Just after close: !  Work with management to develop the 12-24 month operating strategy and plan to reach the identified goals !  Set the consulting budget and schedule ! Plan the level of transfer of knowledge needed after the consultants   finish 17
  • 18.
    Delivery – Focuson the First 18 Months Agree upon the action plan that focuses on the highest priorities ! I mpact to EBITDA !  Impact to customer delivery issues and quality !  Impact on inventory to free up cash Typically run 2-4 kaizens while coaching and training the internal leadership to ‘fish’ themselves Activity tapers from leading the kaizens to coaching the internal team to run the kaizens Many clients end with training programs on critical lean and six sigma tools that are most applicable to their business 18
  • 19.
    Reese Bourgeois reesebourgeois@flowconsulting.com 386.208.6146 www.flowconsulting.com Tell me and I forget; Teach me and I remember; Involve me and I learn. - Ben Franklin CONFIDENTIALITY NOTICE: The contents of this document including all words, graphics, and other materials contained herein are the exclusive confidential and proprietary property of Flow Consulting, Inc. No portion of the enclosed may be copied, reproduced, transmitted, disseminated, or used in any manner without first obtaining the written permission of Flow Consulting, Inc. Live Oak, Fl, USA.
  • 20.
    Case Study Background NewYork Based Private Equity Firm Had Signed Letter of Intent – Truck and Fire Engine Equipment Manufacturer Board Member and Existing Client Recommended Flow Consulting to Study Operational Opportunities Four Day Intensive Assessment Revealed the Following: ! was 50% of their business in cycle time on largest product line, which  Potential for 75% reduction !  Potential for 40% increase in labor effectiveness on largest product line ! which theto increase capacity by at least 50%withoutneed and mortar,   Potential newly acquired company stated as a dire brick ! Opportunity to reduce costs by at least 15% on 40% of their purchased   commodities through strategic sourcing 20
  • 21.
    Results First Project –data collection and 2 kaizens !  Increased capacity in largest production from 65 units/shift to over 90 units/shift with a reduction of 2 employees !  Manufacturing cycle was reduced from 5 days to 4 hours ! The hourly crew was able to devote an hour nearly every day to   continuously improve by implementing the 150 action items identified in the 2 kaizens Second Project – data collection and 1 kaizen !  Increased capacity on second largest production line by 33% on one product and 20% on second product !  They accomplished this with the same number of employees ! Manufacturing cycle decreased from 1 day to 2 hours   ! I nternal operations team performed at least half of the kaizen facilitation 21
  • 22.
    Results Purchasing Initiative !  Leanprocurement was implemented with 10% price targets for over 40% of the purchases !  Increased payables from 10 days to 30 days to free up $600k in cash ! Trained all purchasing personnel and engineering personnel in   negotiations training and vendor contact controls Training ! Trained all operations, finance, purchasing and material control   personal in Lean Sigma tools ! Trained one process engineer to Black Belt status in Lean Sigma   !  Sold licensing fee for perpetual usage of Flow Consulting Lean Sigma training materials 22
  • 23.
    In Conclusion Within twoyears: ! Profitability increased by 20%   !  Hourly productivity ultimately improved by 40% Our client exited earlier than their targeted three year cycle, but: $9 million investment by our client turned into $30 million in less than three years. Client grew sales while we added nearly free capacity 23