You see, when the economy tanked five or six years ago, we did some serious thinking at Algood. The knee-jerk response of many companies was to cut costs and lay off staff. We weren’t prepared to play that game because our employees are our greatest asset. Instead, we chose instead to re-evaluate and consider what was going to make us a better manufacturer. Many of the efficiencies that resulted from that process are at the heart of our double-digit growth today. One of our conclusions was that our current facility couldn’t support the flow between our various integrated functions like injection molding and metal stamping.
It was over 40 years ago that my father originally acquired the building that we will leave on July 7. In truth, it was only one unit in the building. Over time, as the company grew, we expanded and broke down walls until we occupied all seventeen units of what was supposed to have been unrelated industrial condos. The result is a hodge-podge of contiguous but non-aligned spaces.
Once we’d made the decision to move, finding the right place was the cause of many sleepless nights. It had to be just the right configuration with appropriate access and great potential. Location was a huge factor. We mapped the home addresses of our employees and were determined to find a location that did not increase the commute time for most. In the end, not a single employee is leaving because of the new location.
Interestingly, the search process was also a learning process. I had the opportunity to speak to many manufacturers who were finding innovative ways to use space effectively. Companies were downsizing to smaller spaces not because sales were down but rather because they were looking for the optimal manufacturing flow and configuration. That helped us realize that a building with less floor space but higher ceilings could be more efficient. Our new facility has less square feet but with 30 foot ceilings, we have increased our total space by over 10,000 cubic feet.
Now that the decision has been made and the new facility is taking shape, we can see the vision becoming reality and that’s cool. From the outset we established a moving committee with key players from manufacturing, plant operations, engineering, logistics and sales. We labored over every aspect of the move – each with its multiple choices and outcomes.
And it paid off. We have reduced the maximum walking distance between departments from 550 feet to 225 feet. We have a layout that allows for the perfect manufacturing flow. Production will be even better integrated and in some cases we will shave days off lead times. Incredibly, our new home has the capacity to double our output.
Even so, a move of this magnitude is a massive leap of faith. We are investing over $1 million in the new facility. There are over 2000 new rack spaces, over 70 T5 lighting fixtures that were installed, leasehold improvements and the cost of the move itself.
Our move is an expression of our commitment to North American caster manufacturing and our belief in an even brighter future for Algood Caster Innovations.
9 comments on “We thank the recession for our new facility”
You may have noticed that Algood’s new tagline is The Next Generation of Castersmiths and I would bet your first question is, “What the hell is a castersmith?” I can tell you a lot about Algood by answering that question and explaining the new tagline.
Castersmith is a term that we coined based on all of the qualities that are understood when talking about other smiths – like silversmiths, blacksmiths and locksmiths. What follows is what I believe makes us true castersmiths.
- Craftsmanship. We have mastered the trade of building casters. We manufacture our own casters and wheels we know every part, every ounce of material and every minute of work that goes into creating a quality product. We know every tiny detail that goes into making a caster from beginning to end. Our integrated production facility includes tool & die making, metal stamping, injection molding and assembly – all under one roof.
- Attention to detail. There is no part of the design and production process that is too small to deserve our attention. Our fully resourced R&D and engineering departments make sure that every aspect of a caster’s performance is considered from the outset. We create our own prototypes, test them extensively and modify them until we’ve got it right.
- Pride. Every caster or wheel that leaves our 80,000 square foot manufacturing facility has our name stamped on it. It’s a stamp that says we stand behind our products and guarantee their quality. Through our commitment to ISO testing and compliance, we have achieved a near perfect 99% quality completion rate. As our shipping inserts say, every Algood order is packed with pride.
Here’s what “The Next Generation” part of the tagline is all about. Obviously, we’re the next generation because this is a family owned business and my brother Sean and I have taken over where my father, who founded the company, left off. My father is my hero and I try every day to emulate his dedication to our customers, his creativity in developing products that meet our customers’ needs and his commitment to hard work and honesty.
The Next Generation also means that this is a business that has embraced technology and innovation. We develop our own equipment. We integrate casters with advanced hydraulics and electronics. We are creative and have dozens of patented or patentable products. We have more standard caster configurations than any other manufacturer. Don’t just take our word for it. Algood was recently recognized by a huge Fortune 500 company as its most innovative supplier in 2013.
Far from being a meaningless marketing line, The Next Generation of Castersmiths provides a sense of purpose for all of us at Algood. It is our mission and we aim to live up to it every single day.
7 comments on “What’s a Castersmith, you ask?”
I called this blog “My world is Round” because it’s true. Yeah, I know that Christopher Columbus or Magellan or a Greek philosopher figured out the world is round centuries ago, but the point is that my world is round. I spend most of my life living and breathing casters. And its been that way for 25 years. That’s what happens when you’re the president of one of North America’s largest caster manufacturers that just happens to be a family business. When I was a kid our family life was centered around this caster business. I can still remember going to the plant with my mother to bring my dad dinner on nights that he had to stay late.
My world is also round because I spend so much time traveling the globe – throughout North America, to Europe as well as the Near East and the Orient – seeing customers, suppliers and strategic partners. In posts to come, I’ll talk about how I deal with that part of my world.
But, to start, I wanted to tell you what’s truly important in this round world of mine. Of course, it’s casters. But what I learned from my father – and on my own for the past 15 years – is that there are principles and values that go way beyond what we actually make. There are actually some very old fashioned – you might even say square – ideas that I learned from my dad and that make my world go around. Here they are:
Take pride in what you build and sell. Always strive to do better and don’t ever be satisfied unless you’ve done the very best you can. There is no product or delivery error that is ever tolerable. We may have a 75,000 square foot facility that turns out hundreds of thousands of pieces a year but every caster with Algood stamped on it, comes with our personal guarantee.
Your word and your reputation are worth everything. When you say you are going to do something for a customer, it happens – even if you lose money doing it. When you shake hands on a deal, there’s no turning back. Dishonesty is the slippery slope to failure. Whether you’re one of our customers, partners or suppliers, you’ll always get the straight bill of goods.
Treat your employees with respect and care. Value their contributions. Never take them for granted. Give them the opportunity to reach higher and do more and then reward them when they do it. At Algood, we are proud that we employ almost 100 people in our manufacturing facility. Our employees are our greatest asset – and they know it.
Never compromise your values. Never settle. Never put profit ahead of principle. When you deal with Algood, you’re not dealing with a corporate sub-division. You’re dealing with the people who make all the decisions and are have to live with the consequences. So, there you have it.
This is my round world and I welcome you to it. In the coming weeks and months I look forward to sharing more of it with you. In the meantime, if there’s something about my world that reminds you of yours, or anything else that you’d like to comment on, I’d love hear from you.