Clunky To Scalable: Reengineering A Global Supply Chain To Power Growth
OVERVIEW
TeleAdapt, a $25M global distributor of telecom and power accessories for travellers, was shackled by outdated, manual logistics and a bloated 3PL depot network. Service delays stretched beyond eight weeks. A newly recruited CEO set a bold growth agenda, triple sales over two years, but realised the supply chain’s ability to scale was thwarted by it’s unwieldy design, lack of leadership and lack of systems integration
Trigger for Intervention: A mismatch between growth ambitions and supply chain capabilities
THE CHALLENGE
The operating model was manual, fragmented, and structurally incapable of supporting growth ambitions.
- Manual controls dominated operations. Processes were undocumented and dependent on individual know-how across multiple sites spread globally.
- Depot model drove complexity and cost. Regional inventory holdings added unnecessary handling, expense, and delay.
- No supply-side control. Inconsistent supplier behaviour and long lead times caused erratic stock availability and inflated working capital.
- Service levels were unacceptable. Out-of-stocks routinely triggered 6–8 week wait times for replenishment.
- The network couldn’t scale. The new CEO’s growth targets were incompatible with the current high-touch, low-speed setup.
THE APPROACH
The business turned to Gary Newbury, an expert Supply Chain Management Consultant, to design a scalable, global solution. He overhauled the processes, streamlined operations, and enabled three-day delivery worldwide while removing $8M in cost and $2.5M of excess stock.
- Mapped global flows and pain points. Assessed inventory, fulfilment, and transport dynamics across the UK, Europe, US, China, and Hong Kong.
- Validated issues with top-tier clients. Conducted structured interviews with IBM and Dell to confirm root causes of repeated service failures.
- Built a reengineered supply model. Designed an outsourced, stockless operation anchored in three-day fulfilment and fast-pick order assembly.
- Redesigned system architecture. Configured Navision to support batch tracking, kitting, UoMs optimised for air freight, and client-specific localisation.
- Led adoption and implementation. Worked with leadership and operational teams to embed new processes, standards, and vendor controls.
THE SOLUTION
Execution focused on replacing legacy inefficiency with modern tools, controls, and fulfilment velocity.
- Inventory optimisation. Identified $2.5M of excess and obsolete stock through demand-driven replenishment and tighter controls. Developed a return to supplier program to reduce holdings.
- Cost elimination. Cut $8M in logistics costs by dismantling the depot model and transitioning to door-to-door supply from Asia.
- Fulfilment acceleration. Shifted global service expectation to a three-day window, with next-day for top 25 SKUs in core markets.
- Systems upgrade. Enhanced Navision’s distribution module to enable stockless operations — functionality later adopted into Microsoft’s core product roadmap.
- Warehouse redesign. Transformed the Hong Kong facility into a pack-ready, sub-carton-free, high-speed fulfilment hub, and strategic stocking centre for Top 25 lines.
Not only was this a system issue. It was a growth model stuck in neutral.
THE OUTCOMES
The business was left with speed, control, and a scalable platform for future growth.
- $2.5M in working capital released. Eliminated unnecessary inventory holdings and reduced risk exposure.
- $8M in supply chain costs removed. Locked in through structural simplification, transportation mode switch (from ship to air), smarter sourcing and collapsing the inefficient 3PL depot network.
- Three-day global service standard met. Fulfilment times slashed across all customer regions and premium next-day service established globally.
- Scalable network enabled. Infrastructure ready to support 3x volume without significant overhead increases.
- Greater control and transparency. Fewer errors, tighter data, and streamlined operations.
WHY IT MATTERS
The design solved real problems — not just in theory, but in execution.
- High-touch networks drain profit. Depot-led models disguise cost, slow service, and multiply failure points.
- Speed is a growth enabler. Fast fulfilment boosts client confidence and protects margin.
- Execution drives value. Systems only work when they reflect real-world operations and are embraced by the teams who run them.
CLIENT TESTIMONIAL
“We had ambition but no route to scale. Gary Newbury gave us clarity, challenged our assumptions, and delivered a practical plan we could execute. Our supply chain is now running faster, simpler, and without the firefighting.”
— Colin Corby, Chief Operating Officer, TeleAdapt