Troy Optimizing Long Lead Material Management for Scalable Manufacturing

The client faced rising complexity in managing global supply chains and long lead materials like PCBAs and semiconductors, which are critical to scaling production and supporting early pilot builds.

With increasingly complex product development cycles and global supply chain pressures, the organization needed a robust approach to managing long lead materials such as PCBAs and semiconductors to support pilot builds, de-risk inventory liability, and ensure a smooth transition to scalable production.

Dedicated Program Management to align Engineering, Sourcing, and Manufacturing around long lead material readiness. Key initiatives included:

• Supplier & Forecast Alignment: Captured pilot requirements, met regularly with suppliers, and coordinated internal forecasting to ensure material, tooling, and fixture readiness.
• Scenario & Risk Analysis: Modeled the impact of shortages and design changes, balancing inventory positioning with liability risk to ensure resilient supply planning.
• Metrics-Driven Management: Tracked KPIs like days of supply, E&O, shortages, and inventory exposure to drive accountability and improve supplier performance.
• Pilot-to-Production Readiness: Led the transition from pilot to growth by validating BOM accuracy, forecast integration, and material scalability.
• Cross-Functional Program Leadership: Managed competing priorities across teams, resolving blockers and aligning stakeholders on timelines, requirements, and strategy.

• Identified and implemented process improvements that enhanced global supply alignment and tool efficiency.
• Improved supply chain responsiveness and reduced risk from component shortages.
• Enabled smoother pilot-to-growth transitions through proactive BOM and forecast planning.
• Increased transparency and trust between internal teams and external suppliers.