Dan McMillen
Dan McMillen

Dan McMillen

Strategy that ships.

Nashville, TN

I solve complex business problems by getting to the root cause and building systems that actually work.

With more than 20 years of experience across consumer electronics, aerospace and defense, and industrial manufacturing, I've led transformations inside billion-dollar enterprises and mid-market manufacturers alike.

My approach is rooted in fundamentals. Before proposing a solution, I dig into the underlying mechanics—whether that's re-deriving profit calculations to find what's really driving margins, or mapping out a convoluted process to discover why it keeps breaking. I stay accountable through delivery, not by handing off a deck and walking away.

Case Studies

A selection of projects demonstrating deep problem-solving, system design, and measurable business impact.

Consumer Electronics $1B+ Revenue

Uncovering Hidden Revenue Loss

Challenge

Leadership suspected third-party sellers were undercutting genuine product sales on a major marketplace, but had no way to measure the impact.

Approach

Built custom web scraping tools to identify and track non-genuine listings. Developed algorithms to estimate third-party sales volume and connected the data to internal metrics.

Result

Discovered non-genuine sales were significantly higher than estimated—impacting millions in revenue. Leadership gained visibility into a hidden problem, enabling targeted enforcement and channel strategy changes.

Revenue Analytics Marketplace Strategy Data Engineering
Aerospace Manufacturing Mid-Market

Government Bid Optimization

Challenge

Inside sales spent hours manually calculating government contract bids. Complex pricing rules meant mistakes either lost deals or left money on the table.

Approach

Reverse-engineered the complete government bidding system. Derived mathematical relationships that optimize bid pricing and built an automated tool for the sales team.

Result

Bid preparation dropped from hours to minutes. Removed guesswork, reduced errors, and freed the team to focus on winning deals instead of spreadsheet work.

Process Automation Sales Operations Government Contracts
Consumer Electronics $1B+ Revenue

Fixing Broken Forecasting

Challenge

Monthly sales reports showed erratic seasonality that didn't match reality. Leadership couldn't trust the data for planning, and no one could explain why.

Approach

Investigated the full data pipeline from retail partners to internal reporting. Discovered retail calendar conventions were creating artificial distortions. Re-derived correct formulas.

Result

Forecasting accuracy improved immediately. Planning teams finally had data they could trust—improving every downstream decision that depended on seasonality patterns.

Demand Planning Data Quality Supply Chain
Industrial Equipment Mid-Market

Engineering Documentation Automation

Challenge

Engineers spent significant time manually creating complex assembly drawings. The process was slow, error-prone, and pulled technical talent away from higher-value work.

Approach

Broke down all components of the technical drawing process. Identified patterns and rules that could be systematized. Programmed a complete automation solution.

Result

$200,000 in annual savings. The system is still running 17+ years later—a testament to building solutions that last.

Business Process Automation Engineering Efficiency Technical Systems
Consumer Health Fortune 500

Retail Kiosk Network Optimization

Challenge

A nationwide network of retail kiosks was underperforming. The company needed to optimize placement across thousands of locations but lacked a systematic approach.

Approach

Identified primary performance drivers using big data analytics—store traffic, demographics, category-specific factors. Built a scenario modeling tool with geographic visualization.

Result

Reallocated 158 kiosks and added 512 new locations based on data-driven optimization. Net result: $10M increase in annual sales.

Location Analytics Retail Optimization Predictive Modeling
Consumer Packaged Goods Fortune 500

Portfolio Rationalization at Scale

Challenge

A major CPG company needed to reduce SKU count but couldn't align internally on which products to cut. A previous 9-month engagement with a top consulting firm had failed to deliver a workable solution.

Approach

Built a complete market simulation linking product decisions to financial outcomes. Created scenario modeling tools that connected SKU changes to actual margin impact.

Result

Delivered a working solution in 8 weeks. Enabled 20% SKU reduction with full organizational alignment. Teams moved from reactive analysis to proactive strategy.

Revenue Management SKU Rationalization Market Simulation
Premium Confectionery Global Brand

Category Captain Recognition

Challenge

A premium chocolate brand needed to establish category thought leadership with major retailers to influence shelf placement and category strategy.

Approach

Developed a comprehensive thought leadership platform grounded in shopper insights. Created retailer-specific strategies and compelling data-driven presentations.

Result

Won Progressive Grocer 'Category Captain' award—industry recognition for excellence in category management and retail partnership.

Category Management Thought Leadership Retail Strategy
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