The BBC (TopGear)
A comprehensive supply chain transformation for BBC Studios. We engineered an institutional-grade operating system for TopGear, consolidating a fragmented vendor network to protect EBITDA and de-risk global merchandise delivery. Through technical governance and margin engineering, we delivered £182k in annualised savings and an 84% improvement in operational velocity.
Total Annualised Cost Reduction:
£182,000
Operational Velocity:
84% reduction in lead times
System Build:
Transition from fragmented vendor sourcing to a managed Tier-1 ecosystem
01. Strategic Diagnosis & Mission
When BBC Studios approached Onflair to manage the global merchandise operations for TopGear, the primary objective was to de-risk the supply chain and protect EBITDA during a period of rapid category expansion.
The existing infrastructure was fragmented, characterised by decentralised supplier communication, inconsistent quality standards, and high operational volatility. Our mission was to eliminate these "silent cost-drivers" by installing a professional operating system that prioritised brand integrity and capital efficiency.
02. The Approach: Engineering Resilience
We initiated a comprehensive Supply Chain Audit to map every touchpoint from design intent to omnichannel fulfilment. Working alongside internal stakeholders, we developed an Operational Roadmap that replaced "gut-feeling" decisions with data-backed cost engineering.
Key Infrastructure Deployed:
Technical Governance: Standardised 10+ tech packs to ensure manufacturing repeatability.
Margin Engineering: Benchmarked material costs and MOQs to uncover £182k in latent savings.
Critical Path Management: Installed a rigid milestone framework to protect launch windows.
03. Sourcing & Operational Command
Onflair consolidated a disorganised vendor network into a unified Tier-1 ecosystem. By implementing institutional-grade QC protocols (Inline and Final Inspections), we shifted the factory relationship from "hope-based" to "evidence-based".
As the embedded operations lead, we oversaw the end-to-end lifecycle, coordinating multi-factory production while maintaining tight fiscal control. This "Done-for-You" execution allowed BBC Studios to scale their assortment without increasing permanent internal headcount.
04. The Result: A New Commercial Benchmark
The partnership delivered measurable, bottom-line impact. By reducing lead times by 84%, TopGear moved from a reactive "firefighting" model to a proactive, market-responsive strategy.
With £182,000 in recovered margin and a scalable operational playbook now in place, the merchandise division operates with a level of clarity and control that serves as an internal benchmark for future BBC ventures.
