How TMG Took Rebundle from Negative Margins to Profitability in One Year

The Client

Client: Rebundle, a pioneering beauty brand creating plant-based hair extensions
Industry: Beauty / Personal Care
Stage: Pre-seed

The Challenge

When Rebundle engaged TMG, they were in the red — burning cash fast with no clear path forward. Gross margins were in the negative, labor costs were out of control, and operations weren’t scaling. The business had limited months of cash left in the bank, but lacked the efficiency and infrastructure needed to turn it around. So they called TMG. 

  • Gross margins were in the negative 

  • Labor costs were out of control

  • Operations in St. Louis couldn’t scale

The TMG Solution

TMG executed a three-phase operational overhaul to bring Rebundle from negative margins to profitability in under a year:

  • Cut overhead

  • Create and immediately implement manufacturing efficiency palns

  • Migrate the supply chain across the globe to Africa

What We Did

Phase 1: Cut Overhead

TMG restructured Rebundle’s team and operations to lower overhead and create a leaner, more agile operation.

  • Replaced three full-time employees with one fractional operator, not only lowered costs but also it allowed the team to move faster, with less internal friction and clearer ownership across operations.

  • Reduced the core team from 20 part-time employees to 5 full-time employees

Priority 2: Create Plans for and Improve Manufacturing Efficiency

With a restructured team in place, TMG had stopped the immediate cash hemorrhage. Quickly, they turned the focus to better use of every dollar spent.

  • Introduced simple, real-time tracking tools to monitor hourly output and identify bottlenecks on the line.

  • Shifted from role-specific labor to fully cross-trained team members, increasing staffing flexibility and reducing idle time.

Sequenced production for maximum efficiency and cost savings

Priority 3: Build a Foundation for Scale

  • Rebuilt demand planning processes from scratch to improve forecast accuracy and reduce over-ordering

  • Developed and implemented a full order-to-cash system—including POs, invoicing, payments, and inventory control

  • Reorganized warehouse workflows to reduce turnaround time, improve accuracy, and prepare for retail compliance

  • Introduced ABC inventory classification and safety stock thresholds to balance availability with working capital needs

Priority 4:  Migrate Supply Chain to Africa

Once the domestic operation was stabilized, TMG fast-tracked a global transition.

  • Fast tracked migration to multiple African manufacturing partners for cost, quality, and scalability – expediting timeline by a year.

  • Built a 12-week roadmap to shift all production offshore without disrupting fulfillment or product quality.

Created a scalable infrastructure for future expansion into Kenya and South Africa.

Results

73% Gross
Margin Swing

From -13% to +60% thanks to a completely rebuilt supply chain.

106% Increase in
Output with a 70%
Reduction in CPU

 Output increased while costs dropped.

Profitability in
under 12 months

From bleeding cash to breaking even — and then some.

Why It Worked

This wasn’t just a cost-cutting exercise. It was a strategic rebuild. TMG helped Rebundle do more with less—trimming overhead, boosting productivity, and installing a global supply chain that made profitability possible.

From burn to break-even, Rebundle proved that operational excellence is a growth strategy.