Manufacturing plant recovery

We take over manufacturing plants under pressure.

  • 5 days to diagnose.
  • 10 weeks to stop the bleeding.
  • 20 weeks to sustain.

The 5-10-20 method, used in 100+ recoveries across medical, defense, aerospace, and Tier-1 automotive.

Most plant breakdowns are not caused by suppliers. Not by demand peaks. Not by geopolitics. They are self-created, and they follow a formula.

  • Low process maturity
  • High product complexity
  • High people dependency

Then one external shock:

  • A demand spike
  • A supply shortage
  • A cyber incident

And the formula breaks the plant.

We solve the formula. Not the shock.

Typical pattern we see

The Turnaround Blueprint by Frederic Gomer

Read the method:
The Turnaround Blueprint

Twenty years of plant recoveries, compressed into one book.

Every recovery follows the same sequence. We stopped keeping it in our heads and wrote it down: the diagnostic questions, the week-by-week rhythm, the mistakes that cost us the first ten years, the five conditions we now refuse to work without.

If you are the one the board is looking at when the plant stops shipping, this is the book to read before your next Monday.

Read by 3,000+ operations leaders in medical, defense, aerospace, and Tier-1 automotive.

Selected engagements · client names redacted

Recent recoveries.

01 · US · Defense equipment plant
  • Late backlog$15M → $6M
  • On-time delivery53% → 92%
  • Revenue recovered$12M in Q1
  • Timeline10 weeks
02 · Mexico · Medical device plant
  • Post-M&A backlog5.7M → 250K units
  • Timeline12 weeks
  • ContextFailed integration recovery
03 · Thailand · Automotive Tier-1
  • On-time delivery30% → 97%
  • Late backlogCleared to zero
  • Timeline3 months
  • Engagement fee$25K entry
04 · Europe · Aerospace ramp-up
  • Program status6 months late → full rate
  • Time to full rate3 months
  • DeliveredUnder contract

Client names redacted for confidentiality. Verifiable references available on request.

Unedited references from ex-clients

What clients say.

Frederic is not your typical consultant. He thinks like a strategist and executes like a plant manager.

We ran two complex projects together:

  • Built a distribution center in Germany from scratch in 4 months & led the transfer with 0 disruption.
  • Turned around a plant in Slovakia in 6 months. Both came in on time.

Both hit their business case.

The thing you don't see on the résumé: he can walk into a room of angry stakeholders on a bad day and walk out with a plan everyone commits to.

That is a rare skill.

If you have a difficult plant that has to work, and has to work fast, Frederic is the operator I would call first.

Ex-client · Jose Torrao, Supply Chain Director, Schindler

Manufacturing turnarounds don't happen in conference rooms. They happen on the floor, on Gemba. That's where B2G's office is.

Fred and his team work directly in the operation, alongside the people who actually run the business. They identify the real issues, build practical solutions, and most importantly execute those solutions in a way that holds after they leave.

If your manufacturing operation needs more than a report, if you need experienced people in the operation driving results, I strongly recommend Fred and his team.

Ex-client · Greg Marks, Plant GM, Valeo

We acquired a medical device plant in Santo Domingo that looked clean on paper. Six months in, the backlog was at +10,000 units and customers were escalating to the board.

Frederic and his team were on the floor within a week. Twelve weeks later the backlog was under 700 units, and our two largest customers had stopped calling us, not because they gave up, but because we were shipping.

He doesn't confuse activity with progress. He fixes the two or three things that actually move the P&L and ignores the rest.

If you have a plant in your portfolio that has to be recovered before the next board meeting, Frederic is the operator I would put on it.

Ex-client · Ben C., CEO (confidential)

The 5-10-20 method

Three phases. One rhythm. One outcome.

Day 5
Diagnose
Week 10
Stop the bleeding
Week 20
Sustain
Phase 01 · Days 1–5

Diagnosis

On the shop floor within 5 business days. Senior operators only. No juniors.

You get

  • Root cause of the breakdown
  • 12-week recovery plan
  • Business case with financial impact
Fee: $25,000. Fixed. No slides.
Phase 02 · Weeks 1–10

Stop the bleeding

2–4 senior operators embedded on-site. Daily rhythm. Weekly recovery targets.

Focus

  • The 3–5 operational fundamentals that move the P&L
  • Backlog burn-down
  • Customer stabilization
  • Nothing else
Daily on the floor. Weekly with your leadership.
Phase 03 · Weeks 10–20

Sustain

We rebuild the routines that make the recovery hold after we leave.

Focus

  • Shop-floor rituals your team owns
  • Planning rhythm handed to your leaders
  • Zero dependency on us at week 20
We leave when the plant runs without us.

Before we start.

Five conditions agreed before we set foot in the plant.
Not to protect me. To protect you.

  1. 01
    Full authority on operational decisions.

    So decisions move in hours, not weeks.

  2. 02
    One recovery team, one accountability.

    No matrix. No silos. Clear ownership, from shop floor to boardroom.

  3. 03
    Action before cost-cutting.

    So recovery is real, not accounting. Cost comes back after the plant works, not before.

  4. 04
    Open communication with your angriest customer.

    Trust is rebuilt in the open. We reach out to them directly, on your behalf, from week one.

  5. 05
    Clear handover at week 20.

    Your team owns the outcome, not us. We leave when the recovery holds without us.

Sectors

  • Medical devices
  • Defense
  • Aerospace
  • Tier-1 automotive
  • Industrial equipment
  • Engineered systems

Geographies

  • Latin AmericaMexico, Puerto Rico, Costa Rica, Dominican Republic
  • United StatesMinnesota, Ohio, Michigan, California, Texas, Massachusetts
  • Western EuropeFrance, Germany, UK, Switzerland
  • Eastern EuropePoland, Czech Republic, Slovakia
  • Southeast AsiaMalaysia, Singapore, Vietnam, Thailand

Meet the operators

Nine senior operators across four continents. Average 20+ years on the shop floor.
No juniors. No analysts. No pyramid.

Frederic Gomer

Frederic Gomer

Engagement Director

Frederic has led plant recoveries for two decades across medical, defense, aerospace, and Tier-1 automotive. Past engagements include turnarounds, ramp-ups, and industrial transfers for Schindler, Smiths, and Faurecia. He leads every B2G engagement personally and is the author of The Turnaround Blueprint, which codifies the 5-10-20 method used in 100+ recoveries.
Maximo Ulloa

Maximo Ulloa

Turnaround & Operational Excellence PMO

Maximo has led turnarounds for Tyco, Trillium Flow Technologies, and Smiths. His work centers on shop-floor execution and production control. On every engagement he captains the recovery team on the ground, identifying, escalating, and resolving issues in daily rhythm.
Mark Lado

Mark Lado

Manufacturing & Quality Excellence Lead

Mark has led manufacturing and quality transformations globally, including engagements at GE, Jabil, TRW, and Saturn across China, Malaysia, and the USA. Documented outcomes include doubling productivity and cutting quality defects by 30%. He is the author of Building a Showcase Culture: Powerful and Practical Keys for Manufacturing and the fiction A Shiny New Toy, both available on Amazon.
Joseph Ujczo

Joseph Ujczo

Manufacturing Operations Lead

Joseph has led manufacturing operations improvements for Rolls Royce, Pratt & Whitney, and Alcoa. His work centers on one-piece flow implementation and throughput acceleration.
Pablo Sanz Sanz

Pablo Sanz Sanz

Lean Manufacturing Lead

Pablo has led lean manufacturing transformations across the US, Canada, Switzerland, and multiple European countries. Focus areas: delivery time reduction, on-time delivery improvement, cost optimization, inventory reduction, and equipment efficiency. Anchored in the Lean Thinking principle of "Respect for People."
Alejandro Martinez

Alejandro Martinez

Interim Plant Management Lead

Alejandro has 30+ years in manufacturing, including 13 years carrying full plant P&L. He has served as Engineering Manager, Program Manager, and Production Manager across multiple sectors. Fluent in English and Spanish. Mechanical Engineering background with an MBA in Finance. Expertise spans safety, lean manufacturing, quality systems, supply chain, and union affairs.
Salma Benhaddou

Salma Benhaddou

Turnaround Digital Solutions Lead

Salma leads the rollout of B2G's digital solutions during recovery engagements: dashboards, forecasting tools, quality metrics, planning applications. She is the architect of the B2G EVO suite (EVOflow, EVOview, EVOplan, EVOstock), designed to give clients clear visibility on recovery progress from shop floor to boardroom.
Greg Marks

Greg Marks

Lean Operations & Supply Chain Lead

Greg leads lean operations and supply chain workstreams during B2G recoveries. His expertise covers material flow, inventory strategy, and shop-floor rhythm design.
Djamel Rezzig

Djamel Rezzig

Logistics & Material Management Lead

Djamel leads logistics and material management workstreams during B2G recoveries, with focus on inbound flow, warehouse operations, and material handoff to production.

Where we've worked.

Operators from our team have led recoveries at:

Schindler
Smiths Interconnect
Faurecia
Valeo
MicroPort
KGN

On-site within 5 business days worldwide.

Talk to us

If your plant fits the pattern.

Three recoveries per quarter.
Write to us directly with what you're seeing.

Request a meeting

or write to contact@b2g-consulting.com

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