We diagnose inefficiency, implement solutions, and measure the results — in 90 days. Compensated only when you win.
Working exclusively with industrial manufacturers & distributors generating $75M – $400M in revenue
Most mid-market manufacturers and distributors are operating with processes, systems, and cost structures that haven't been stress-tested since the business was half its current size. The savings are there. The expertise to find and capture them typically isn't.
Morrell Consulting exists to close that gap — bringing Amazon-scale operational methodology directly to the $75M–$400M industrial market, at a price structure that makes the engagement a straightforward ROI decision.
Every engagement follows the same disciplined structure — diagnostic, implementation, measurement — with fees tied entirely to the savings we deliver. You'll know exactly what you're paying, exactly when you're paying it, and exactly what you're getting in return.
On-site assessment, stakeholder interviews, and deep data analysis across your warehouse, labor, freight, and inventory operations. You receive a quantified opportunity inventory, a prioritized savings roadmap, and a proposed implementation scope — built on your actual numbers, not industry averages.
We work directly inside your operation — not from a PowerPoint deck — to design, test, and deploy improvements across the identified opportunity areas. Before a single change is made, both parties sign off on the baseline methodology and measurement approach. No surprises at invoice time.
Savings are measured against the agreed baseline over a 30-day window — or longer if your operation requires it. Results are verified and signed off jointly by your CFO or Controller and our team. The fee invoice follows sign-off, not the other way around.
Following a successful engagement, select clients are offered an ongoing monthly retainer — an embedded operational partner for continuous improvement, KPI management, and executive advisory.
Five core service lines, all grounded in Lean and Kaizen methodology, and all delivered through the same diagnostic-to-implementation engagement model. We don't consult from the outside — we work from the inside.
Every engagement begins here. A structured 14–21 day assessment covering your full operational footprint — warehouse, labor, freight, inventory, and systems. We produce a quantified opportunity inventory ranked by savings potential, a prioritized implementation roadmap, and a proposed Phase 2 scope. The diagnostic is priced to be a straightforward decision for an $80M+ company and designed to generate a savings roadmap that makes the implementation a no-brainer.
Audit your carrier portfolio, analyze lane performance, right-size mode selection, and renegotiate contract terms. Freight-to-revenue is one of the highest-leverage cost levers in mid-market distribution — and one of the most consistently underoptimized.
Reduce carrying costs, eliminate slow-moving and obsolete inventory, and sharpen your replenishment logic. SKU proliferation is a silent margin killer in manufacturing and distribution — we quantify the cost and build the path to a leaner, faster-turning catalog.
Redesign physical and logical warehouse configurations to minimize travel time, improve pick rates, and increase throughput. Layout and slotting decisions made years ago are costing you labor hours every single day — the fix is often faster and cheaper than operators expect.
Benchmark productivity, identify non-value-added activity, and implement engineered labor standards and management operating systems. Labor is typically the largest controllable cost in a DC — and the place where improvement is most visible, most measurable, and most sustainable.
Facilitate structured Kaizen events, Value Stream Mapping, and continuous improvement roadmap development. We don't just identify waste — we build the internal capability to keep finding and eliminating it after we're gone.
Every operation is different. If your most pressing challenge doesn't fit neatly into a predefined service line — whether it's a specific process bottleneck, a systems integration issue, a network design question, or an area surfaced during the diagnostic — we scope it, price it, and solve it. The engagement is built around your operation, not our catalog.
The following are representative engagement profiles. Client details are anonymized by default — references are available upon request for qualified prospects.
Engagement profiles are illustrative and anonymized. Verified references available upon request for qualified prospects.
Most consulting firms send you someone who has studied operations. Morrell Consulting was built by someone who has run them — at the most demanding scale in the world.
Tony Morrell spent years leading building-level operations inside Amazon's first and final mile fulfillment divisions, managing labor, productivity, safety, and continuous improvement across facilities processing millions of units. Before that, he served within GAP Inc.'s internal strategy and operations function — a formal consulting practice — advising across four global brands on supply chain and logistics challenges that spanned procurement, distribution, and last-mile delivery.
What makes that background genuinely useful — rather than just impressive on paper — is how the pieces interact. Operational experience at Amazon's scale develops an instinct for finding waste that most consultants simply don't have: the ability to walk an operation and know, before the data confirms it, where the friction is hiding. Formal consulting methodology from GAP provides the discipline to structure findings, build a rigorous business case, and drive cross-functional alignment. Deep academic grounding in supply chain ensures the solutions aren't just operationally sound — they're strategically coherent. Together, those three lenses produce recommendations that are faster to diagnose, more defensible to leadership, and more durable once implemented.
The result is a firm that can engage with mid-market industrial operators at a level most boutique consultants can't match — and deliver it with a speed and directness that larger firms won't. Wherever your operation is, if the opportunity is real, we're interested in the conversation.
Morrell Consulting maintains a narrow, deliberately defined client profile. Not because we can't work with others — but because focus is what produces the best outcomes for the clients we do take on. Every engagement we accept meets the same criteria.
Multi-SKU producers with complex inbound, production-adjacent, and finished goods distribution challenges. Typically operating multiple DC locations with fragmented carrier portfolios and labor productivity gaps that have grown with the business.
Regional and national distributors carrying freight spend above 5% of revenue, SKU portfolios that have expanded faster than slotting logic has kept up, and DC operations designed for a smaller, simpler operation than the one running today.
CFOs and Operating Partners actively seeking validated EBITDA improvement ahead of hold-period optimization or exit. A 1–2% operational efficiency gain at a $150M company with an 8x exit multiple can translate to $12M–$24M in enterprise value — making a Morrell engagement a straightforward investment decision.
If you're running a mid-market industrial operation and you believe there are material savings you haven't been able to capture — we'd like to hear about it. The initial conversation is straightforward: tell us what you're dealing with, and we'll tell you honestly whether we think there's an engagement worth scoping.
No commitment, no pitch deck. Just a direct conversation with Tony.
We'll review your situation and respond within one business day with an honest assessment of whether a diagnostic makes sense.