Fractional Operations Leadership

Turn operational complexity into profitable growth.

Sagamore helps middle-market manufacturing and distribution companies improve service levels, productivity, quality, working capital and EBITDA—without adding unnecessary corporate overhead.

Operating Experience
ManufacturingDistribution
>95%
OTIF achieved on strategic accounts
98%+
Inventory accuracy achieved
60%
Reduction in overtime
90%
More deliveries without added fleet
When Growth Outpaces Operations

Strategy is only valuable when the operation can deliver it.

Revenue is growing, but service, margin and cash flow are not keeping pace. Inventory is rising. Overtime has become structural. Technology investments are underperforming. The CEO is spending too much time managing operations.

Sagamore brings experienced COO-level leadership into the business—establishing the facts, prioritizing the value and working alongside management to strengthen culture and capabilities and produce measurable results.

How We Help

Executive leadership.
Operating discipline.
Measurable outcomes.

01

Fractional Operations Leadership

COO-level leadership to stabilize performance, execute change, support growth and strengthen the internal management team and Operations culture.

Explore the approach ↗
02

Operational Performance

Improve service, throughput, inventory, quality, productivity, working capital and operating cost across the end-to-end operation.

See the impact ↗
04

Technology, Automation & AI

Make ERP, WMS, analytics, automation and AI earn their keep by tying investment directly to operating and financial outcomes.

Read our perspective ↗
When Companies Call Us

When operational performance becomes a constraint on the business.

The trigger is rarely “we need a fractional COO.” It is usually a business problem that management has not been able to solve fast enough.

Growth is outrunning operations.

Demand is up, but capacity, service, quality or leadership bandwidth is not keeping pace.

EBITDA is not following revenue.

Overtime, inventory, freight, shrink, rework or operating complexity is absorbing the value of growth.

Technology is not delivering ROI.

ERP, WMS, analytics, automation or AI investments are not translating into better decisions or performance.

A major transition is approaching.

Expansion, succession, acquisition, exit or a new operating model requires experienced implementation leadership.

Manufacturing operation
Manufacturing

Improve flow, capacity, quality and delivery reliability.

From scheduling, material availability and maintenance to production performance, quality systems, automation and technology enablement.

Manufacturing experience ↗
Distribution operation
Distribution

Convert warehouse and logistics performance into competitive advantage.

Improve service levels, inventory turns, labor productivity, warehouse flow, transportation, routing, 3PL performance and fulfillment economics.

Distribution capabilities ↗
Manufacturing Experience

Experience across complex, regulated and capital-intensive manufacturing.

Before founding Sagamore Executive Advisors, Bill Lenihan spent decades helping global manufacturers improve operations, supply-chain performance, predictability and technology effectiveness. Today, he scales those practices for middle-market organizations so they are practical, affordable and implementable.

01

Semiconductor & Microelectronics

Capital-intensive manufacturing involving complex planning, materials, quality, technology and global supply chains.

02

Pharmaceutical Manufacturing

Large-scale, highly regulated operations where quality, compliance, traceability and reliable execution are essential.

03

Medical Devices

Precision products, regulated quality systems, automated distribution and international commercial readiness.

04

Forest Products, Paper & Packaging

Pulp, paper, paperboard, corrugated packaging and related manufacturing and distribution operations.

05

Specialty & Industrial Chemicals

Process operations involving asset utilization, customer segmentation, supply-chain complexity, safety and regulatory requirements.

06

Display Technology

Startup commercialization requiring global sourcing, manufacturing strategy, ERP and scalable supply-chain infrastructure.

Representative experience includes work performed during Bill Lenihan’s career before founding Sagamore Executive Advisors. Company names are withheld where appropriate to preserve client confidentiality.
6 Additional Case Studies

Performance improvement that creates enterprise value.

Representative engagements are presented by industry to preserve client confidentiality. Several were completed during Bill Lenihan’s prior consulting and operating career.

Specialty Chemicals Company

Changed the business model from selling chemicals to selling guaranteed outcomes.

Segmented customers by what they valued, exited structurally unprofitable business and moved service-intensive customers to outsourced water-treatment performance.

115%improvement in margin
10%revenue growth
Outcomebased service model replaced commodity-oriented selling for target customers
Medical Device Manufacturer

Built the operating platform for European expansion while doubling U.S. manufacturing capacity.

Expanded manufacturing, quality, sterilization and packaging capabilities, then established a European HQ and automated distribution operation integrating CRM, ERP, WMS, WES, carousel picking and packaging.

100%increase in manufacturing capacity
90 → 98%quality performance
95%reduction in unplanned downtime
$25MEuropean revenue in first full year
Fruit & Produce Distributor

Restored service and capacity in a $125M family-owned business.

Reorganized operations, installed process ownership and metrics, strengthened leadership and increased throughput without adding warehouse space.

>95%OTIF for A-segment customers
99.6%fill rate
65%reduction in overtime
<0.9%shrink as a percent of revenue
Appliance Distributor

Built a profitable-growth agenda following an unexpected succession.

Aligned leadership, expanded channels, improved procurement and redesigned warehouse, inventory and logistics processes.

$10M+growth and cost opportunities identified
10%eCommerce revenue growth
2%reduction in COGS through improved terms
85%reduction in product returns
Lighting Distributor

Improved EBITDA and strengthened readiness for a successful sale.

Combined reverse diligence with rapid operational improvements, better analytics and more disciplined commercial decision-making.

1 → 3.75%EBITDA improvement
25%reduction in warehouse operating cost in six months
10%increase in bid win rate
18 mo.from decision to successful acquisition
Display Technology Company

Built the global supply-chain and technology foundation for a high-growth new business.

Partnered with leadership to source display materials, chips and components across Asia, Europe and the U.S.; establish an Asian manufacturing plan; and implement the first SAP Lite environment.

Globalsourcing across Asia, Europe and the U.S.
SAPLite operating environment designed and implemented
Scaleoperating platform supported rapid commercialization and growth
How We Work

From diagnosis to sustainable performance.

Sagamore works with the leadership team, not around it. The objective is measurable improvement and an organization and culture capable of sustaining it.

01

Diagnose

Establish the facts, baseline performance and root causes.

02

Prioritize

Quantify value and build an executable roadmap.

03

Mobilize

Assign owners, metrics and operating cadence.

04

Lead

Work alongside management to implement change.

05

Transfer

Build leaders and systems that sustain results.

Engagement Model

Senior operating leadership without adding another permanent executive layer.

Engagements are structured around the business problem, speed required and internal leadership capacity—not around a large consulting team.

Bill Lenihan, founder and Fractional COO of Sagamore Executive Advisors
About Bill Lenihan

Enterprise transformation experience. Middle-market practicality.

Bill Lenihan brings four decades of operations, supply chain and technology leadership—from his family’s wholesale distribution company to McDonnell Douglas, IBM, Mercer Management Consulting and Accenture.

After leading transformations for large global companies and building and selling his own technology business, Bill now focuses on middle-market and family-owned organizations where experienced leadership can create immediate, enduring value.

View Bill on LinkedIn ↗
Executive Insights

Ideas that turn operational complexity into enterprise value.

Perspectives for CEOs and investors connecting strategy to operating performance, profitable growth and stronger decisions.

← Back to insights
Culture & Performance · Executive insight

Culture as a performance lever.

Why the best-run manufacturers and distributors treat culture as an operating asset with measurable performance consequences.

Culture · Executive Insight

Culture as a Performance Lever: Why the Best-Run Manufacturers and Distributors Treat Culture Like a Capital Investment

A perspective for CEOs and owners of middle-market manufacturing and distribution companies

Every CEO I've sat across the table from — first at Deloitte and then as a principal at Mercer Management Consulting and partner at Accenture, and IBM, and now advising middle-market manufacturing and distribution companies at Sagamore — has said some version of the same thing: “Our people are our biggest asset.” Far fewer run their business as if they believe it.

That gap matters more today than at any point in my career. Labor is tight, margins are under pressure, and the tools available to differentiate on price or technology alone are shrinking. What's left — what's always been left, if we're honest — is how well an organization operates day to day. And how an organization operates is a direct function of its culture.

This isn't a soft-skills argument. It's an operating argument. Culture is the multiplier on every other investment you make in your business. Improve it, and you improve retention, efficiency, and quality — and you reduce the overtime premium that quietly erodes EBITDA in almost every plant and distribution center I've walked. Ignore it, and you will keep paying a tax on everything else you try to fix.

The case, in numbers a CFO will accept

Consulting firms have spent thirty years trying to quantify what good operators have always known intuitively. The data is now hard to dismiss.

Gallup's long-running meta-analysis — covering more than 180,000 business units across dozens of industries — is the most rigorous evidence base in existence on this question. Comparing top-quartile to bottom-quartile business units on employee engagement, Gallup finds turnover runs roughly a fifth lower in high-turnover organizations, and around half lower in already-stable ones. On the operating metrics that matter most to a manufacturing or distribution CEO, the pattern holds: highly engaged teams post materially fewer safety incidents, and quality defects drop by roughly a third. Engagement is also tied to sharply lower absenteeism, and — at the “thriving” end of Gallup's scale — to sustained productivity and profitability advantages over peers.

Translate that into your P&L: fewer defects means less rework and scrap. Lower turnover means fewer open requisitions covered by mandatory overtime. Fewer safety incidents means lower workers' comp experience and less downtime. These aren't HR metrics — they are the exact levers Sagamore is retained to pull on service level, productivity, quality, working capital, and EBITDA. Culture doesn't sit next to those levers. It's underneath them.

McKinsey's organizational research tells a similar story from a different angle. Their global database, built on the Organizational Health Index across more than a million and a half respondents, consistently shows that companies pursuing both performance and organizational health outperform those chasing performance alone. McKinsey is candid about the difficulty of getting there, though — even with that evidence in hand, only roughly one in four large-organization transformations achieve lasting success. Culture change is not a slogan-and-poster exercise. It is disciplined, sequenced, leader-led work, and most companies underinvest in the sequencing.

BCG's client work points to the same conclusion from the results side: companies that pair genuine culture change with strategic transformation see outsized gains in total shareholder return, EBIT growth, and revenue relative to peers who treat the two as separate efforts — an advantage that's genuinely hard for competitors to copy, because unlike price or product, culture can't be bought off a shelf.

What actually moves the needle

Strip away the consulting-firm branding, and three findings recur across McKinsey, BCG, Bain, Deloitte, and Accenture's client engagements.

  1. Leaders have to change their own behavior first, visibly, before anyone else's behavior changes. McKinsey's work with large operating organizations is consistent on this point: culture shift begins with clear, visible changes in the behavior of leadership itself, not with a values statement circulated by email.
  2. Sustainable change engages three things at once, not one. BCG frames this as leading with the head, the heart, and the hands — vision and priorities, motivation and empowerment, and disciplined execution. Their client data is specific: transformations that engage all three see roughly a 96 percent chance of sustained success, while most transformations only ever address the head and the hands and leave the heart out entirely. Most manufacturing and distribution leadership teams I've worked with are strong on strategy and strong on execution — lean, Six Sigma, operational excellence — and structurally weak on the heart. That imbalance is exactly why so many operational-improvement programs deliver a burst of gains that decays within eighteen months.
  3. You have to measure culture with the same discipline you apply to inventory turns or on-time delivery. The organizations that sustain gains treat culture as a metric to be benchmarked, tracked, and reported to the leadership team, not a mood to be sensed. Do you know your voluntary turnover rate by shift and by tenure cohort? Do you know why your best machinists or your best inside sales reps actually leave? If the honest answer is “not precisely,” that's the starting point — not a survey program.

The manufacturing playbook

Manufacturing culture work has a few characteristics that distribution doesn't share as acutely, and Sagamore's clients tend to feel them immediately.

The floor is where culture is decided, not the boardroom. Deloitte's research on frontline manufacturing engagement is blunt about the structural challenge: the physical, shift-based nature of manufacturing operations makes communication and listening genuinely harder than in an office environment, and decisions made in the corner office frequently never make it to the factory floor intact. If your plant managers are the only translation layer between corporate intent and shift-level behavior, your culture is only as strong as your weakest plant manager.

Retention is now a production-capacity constraint, not just an HR line item. The scale of the problem is significant: Deloitte and The Manufacturing Institute's research suggests as many as 1.9 million manufacturing jobs could go unfilled by 2033 if the industry can't close its skills and applicant gaps, and in one recent industry survey, nearly half of manufacturers reported having to turn down business because they lacked the workforce to staff it. That is a top-line growth constraint masquerading as a people problem. When an experienced operator walks out the door, the cost isn't just recruiting and training — it's the loss of what one industry analysis calls tribal knowledge: the unwritten procedures, the machine quirks only that person understood, and the working relationships that kept the line running smoothly. The remaining crew absorbs the gap through overtime, quality slips, morale erodes, and — predictably — more people leave. That is the overtime-and-quality spiral this article's thesis is built on, and it is entirely addressable.

Autonomy at the point of production drives both retention and quality. Deloitte's manufacturing workforce research describes a shift already underway among better operators: leading manufacturers are extending more autonomy and control to frontline workers, letting them manage more of their own work as long as the job gets done safely, on time, and to spec. This is a genuine culture shift for command-and-control shop floors, and it's one of the highest-leverage changes a plant leadership team can make — it improves engagement and, done with the right guardrails, doesn't sacrifice quality control.

McKinsey's basic-materials case is worth internalizing. A basic-materials manufacturer that pursued integrated operational and cultural change — not a bolt-on engagement program, but new management practices tied to a genuine shift toward a continuous-improvement culture — used the resulting momentum to apply advanced analytics to its raw-material processing footprint, adding a further 20 percent productivity gain on top of earlier improvements. The full initiative ultimately delivered more than $60 million in bottom-line benefit, roughly twelve times the scope originally envisioned. The lesson for a $50–500 million manufacturer isn't the dollar figure — it's that culture and operational improvement compound each other. Treat them as separate workstreams and you leave most of the value on the table.

The distribution playbook

Distribution and 3PL operations share manufacturing's frontline, deskless-workforce challenge, but the economics and pressure points differ.

Deskless workers are systematically the least engaged, and distribution is disproportionately deskless. Gallup's broader workforce data is direct on this: frontline and deskless employees, who make up the majority of workforces in manufacturing, distribution, healthcare, and retail, are predominantly on-site and consistently report the lowest engagement levels of any work arrangement — partly because most engagement tools and communication channels are still designed for people who sit at a desk. If your distribution center workforce is reached only through a break-room bulletin board and a supervisor huddle, you're competing for talent against employers who reach the same worker on a phone.

Schedule predictability and fair treatment by direct supervisors are the retention levers that matter most for hourly distribution talent, ahead of compensation alone in most workforce research on this segment. That means the first-line supervisor is your highest-leverage culture role, not your HR department. It's worth auditing whether your supervisors were promoted for tenure and technical skill, or selected and trained for the ability to lead people — those are different competencies, and most distribution operations promote for the former and hope for the latter.

Purpose and growth path close the loop that pay alone can't. Workforce research across manufacturing and distribution roles found that well over half of surveyed workers feel their jobs offer limited career prospects, while a large majority said they'd be interested in roles offering more training and a clearer path forward. Separately, roughly half of surveyed workers said they had left a job because they felt unappreciated, and about two-thirds said they'd work harder if they believed their contributions were actually noticed by management. In a distribution operation running lean on supervisory headcount, a structured recognition cadence and a visible, even modest, career ladder from picker to lead to supervisor is inexpensive relative to the fully loaded cost of turnover — and it directly targets the two most commonly cited reasons people leave.

What this means for you as CEO

None of this requires a multi-year change-management program with a seven-figure price tag. It requires the CEO to treat culture as a management discipline with the same rigor applied to working capital or capex:

  • Measure it. Know your turnover by shift, tenure, and role — and know why people actually leave, not why exit interviews say they leave.
  • Start with your own visible behavior, and your plant managers' and DC supervisors' behavior, before you invest in a program.
  • Give your first-line leaders the tools and selection criteria to lead people, not just to run a line or a shift — this is where most of the leverage sits in both manufacturing and distribution.
  • Engage the heart, not just the head and the hands. Your operational-excellence and lean initiatives will underperform their potential if the workforce executing them doesn't believe leadership is genuinely invested in them.
  • Connect the dots explicitly for your leadership team. Lower turnover reduces the overtime premium; higher engagement reduces defects and rework; both flow directly to EBITDA. Say it in those terms in your leadership meetings, and the initiative stops being an HR program and becomes what it actually is — an operating strategy.

The middle-market manufacturers and distributors that will win the next decade won't be the ones with the newest equipment or the cleverest pricing model — those are copyable. They'll be the ones whose people actually want to stay, actually care about the outcome, and actually tell leadership the truth about what's slowing the operation down. That is culture. And it is, in the most literal sense, a performance lever any CEO can pull.

Sagamore Executive Advisors helps middle-market manufacturing and distribution companies improve service levels, productivity, quality, working capital, and EBITDA — without adding unnecessary corporate overhead.

Sources: Gallup Q12 Meta-Analysis (workplace engagement across 183,000+ business units, 53 industries, 90 countries); McKinsey & Company, “Creating a High-Performance Culture” and “The Numbers Behind Successful Transformations”; BCG, “Culture and Change Management Consulting”; Deloitte and The Manufacturing Institute, Manufacturing Talent Studies and frontline engagement research.
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Is the operation ready for what comes next?

Whether the business is growing, underperforming, implementing technology or preparing for a transaction, the first step is a candid conversation about the facts.

Bring the operating issue that is consuming management attention. The conversation can start there.

Growth is outrunning capacityEBITDA is not keeping paceTechnology is underperformingExpansion, succession or exit is approaching