Portfolio Strategy
Why Most Industrial Portfolios Carry 30% More SKUs Than They Should
SKU proliferation is the most quietly expensive problem in manufacturing commerce. Most organizations discover it late — after margin has already eroded and the portfolio has become a burden rather than an asset.
Every industrial executive has felt it. The product portfolio keeps growing. Teams justify each addition — a customer requested it, a distributor needed a variation, the sales team wanted optionality. Years later, the catalog is three times its original size, and somehow margin is harder to defend.
This is not bad luck. It is a structural pattern with a measurable signature. Research benchmarks have documented what it looks like from the inside: active items grow by 31% while total sales increase by only 6%, producing a 19% decline in sales per SKU. The business appears to be expanding. The economics are quietly contracting.
The problem executives cannot see in their current data
Most organizations measure SKU performance with incomplete economics. Revenue per SKU is tracked. Contribution margin, sometimes. But the true cost-to-serve — the complexity costs buried in forecasting friction, changeover time, distributor mindshare, and customer service load — rarely gets allocated accurately to individual products.
Without that allocation, unprofitable SKUs hide inside averages. The portfolio expands because the cost signal arrives late, if at all. This is precisely why cost-to-serve modeling has become a core discipline in supply chain profitability. Organizations that can accurately attribute indirect complexity to specific products and customers are the ones that can make rational portfolio decisions. The rest are managing opinion, not economics.
Why portfolios bloat in industrial and manufacturing commerce
SKU growth in B2B industrial markets follows repeatable patterns. Customer-specific variants get created for a single OEM request and never retired — five years later, they are still being planned, stocked, and supported. Channel partners ask for unique configurations, and each request appears reasonable individually while collectively fragmenting velocity. Innovation pressure gets expressed as breadth rather than depth. And most critically, companies build strong processes for launching products but virtually no governance for retiring them. The portfolio becomes a one-way door.
Harvard Business Review identified this dynamic decades ago: unchecked product-line expansion "disguises cost increases" and disturbs channel relationships. The finding is still current. The only thing that has changed is the scale at which the problem compounds.
Separating good complexity from bad complexity
The strategic question is not whether to simplify the portfolio. It is which complexity is worth paying for. Good complexity creates value that exceeds its incremental cost — a SKU that opens a high-margin segment, anchors a key distribution relationship, or delivers differentiation customers demonstrably pay for. Bad complexity fragments velocity, dilutes distributor mindshare, and consumes planning capacity without corresponding return.
The board-level problem is that most portfolios carry bad complexity because it is emotionally justified — customer requests, sales pressure, legacy relationships — while the true cost remains invisible.
When rationalization happens, the margin signal is significant
The evidence on portfolio rationalization is consistent. In a 2024 packaging industry study, respondents reported that SKU reduction contributed 65 to 90 basis points to gross margin improvement relative to 2019, with further gains expected from continued rationalization. McKinsey describes assortment optimization as redirecting resources from margin-eroding SKUs toward higher-margin opportunities. And in a Bain survey of more than 900 executives, nearly 70% acknowledged that excessive complexity raises costs and hinders profit growth.
Leaders already suspect this. The challenge is not conviction — it is diagnosis.
A CEO-grade test: permission to exist
A practical filter: every SKU in the portfolio should be able to answer for itself. It earns its place if it is a margin anchor with high contribution after true cost-to-serve, a segment doorway that unlocks a profitable target, a channel lever that improves distribution sell-through, or an innovation wedge that creates differentiation customers pay a premium for. If it is none of those, it is portfolio noise — consuming attention, diluting execution, and funding complexity that serves no strategic purpose.
The Kerith lens
Portfolio strategy is not subtraction for its own sake. It is commercial clarity in the face of accumulated decisions that were never designed to work as a system. The companies that scale without strain share one consistent practice: they stop treating portfolio decisions as local, reactive, or sales-driven. They manage the portfolio as enterprise economics — with defined growth metrics, allocated cost-to-serve, governed exit criteria, and protected channel logic.
The portfolio is not a catalog. It is a commercial architecture. Treat it accordingly.