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Reviewing the cap manufacturing and also needlework procedures of Texas-based American Made Cap Co
. In the March 2013 issue of Impressions (" Made in the USA: A Case Study, Part 1 of 2"), I covered a pair of close friends, Greg Bednarik as well as Rickey Eavenson, that made a decision to sustain their neighborhood west Texas economic climate by purchasing American Made Cap Co., a having a hard time cap manufacturer that had gone through several changes in ownership throughout the past three decades, with several employees standing firm via the business's stormy times.
With the brand-new CUSTOM VELCRO PATCHES company owner came brand-new wish for the firm, which I had worked with throughout the "gimmee-cap" boom of the 1970s. During my preliminary go to previously this year, I recognized several areas for improvement, yet the largest challenge stayed finding sufficient clients happy to pay a little extra for a top notch, American-made cap. Determining a complementary item the company could produce or embellish to generate extra earnings was an additional difficulty.
Bednarik revealed that some key employees modifications essentially have actually modified the complexion of their service. At the time of my previous browse through to American Made Cap Co., brand-new Production Manager David Stutts had actually just started working with the company. Stutts was experienced with production in a various market, and also was acquainting himself with the process of production as well as embellishing headwear.
I might tell from his inquiries that Stutts is a very quick study and, since press time, has actually obtained a solid grip of all phases of production. Among the explorations he made is that throughout a previous proprietor's tenure, the needlework device thread trimmers had been turned off to boost stitch result. This benefitted device operators, who were on a reward program. Unfamiliar with the embroidery procedure as well as machine capabilities, this problem was just uncovered after the company paid hundreds of hrs of overtime to employees executing cutting duties.
Additionally, a number of various other new workers are actually making an effect. One has graphic arts skills and display printing experience, and also is being educated to provide back up to digitizer Wanda Eavenson. Another new worker is making contributions in the area of infotech as well as likewise is being cross-trained for various other duties. Both brand-new team members likewise follow up on new company leads.
Development on top of the personnel chain additionally assisted to make changes that improved the staffing in other ways. Among the lessons learned by the ownership is that certain staff members are not always important. It's a typical anxiety among business owners and also management that every little thing will quit if one or more vital workers leave the firm. In my experience, nonetheless, this is seldom the situation. American Made Cap Co. located that in spite of shedding a couple of team members-- including a supervisor-- that manufacturing was maintained without skipping a beat.
By simply observing and also making changes to service techniques, Eavenson as well as Bednarik have actually lowered their everyday procedure prices by $500-$ 600 daily. This has actually substantially improved cash flow and can be credited to numerous key modifications.
A huge change is structured paperwork, which was attained by taking a close take a look at paper circulation within the business and making changes that assisted improve efficiency. Administration additionally placed emphasis on credit card payments for clients, which reduced the management expenses associated with invoicing and also collection.
In the new service arena, four fascinating as well as substantial cap production opportunities have actually been introduced to American Made Cap Co. from companies in Colorado, New York, California and also Texas. At press time, some new accounts were still in the process of being fleshed out, however the brand-new service is offering the capital required to develop a healthy service profile. One of the new accounts sends its very own patterns and products to American Made Cap Co., which provides cut-and-sew plus needlework solutions. Keeping the needlework equipments humming adds to paying the overall overhead costs for the plant.
An additional contribution to the firm's success is its association with the Go Texan program, where it has reaped major advantages. Through affiliation with this program, sponsored by the Texas Department of Agriculture, a firm's name is connected not just with American-made items, however likewise Texas-made products. It was a red-letter day in July when Texas Department of Agriculture Commissioner Todd Staples checked out the business. He acknowledged American Made Cap Co. for its use textile made from American Cotton Growers (based in nearby Littlefield, Texas) in the business's caps, aprons and also tote.
The biggest as well as most promising development the firm has actually experienced throughout the past couple of months is the enhancement of a complementary line of product. The item-- light-weight, flame-resistant garments-- is made use of thoroughly by firms with employees in oil and gas areas. These business likewise use great deals of headwear, making sales calls two times as efficient.
" It's a benefit that the United State government needs workers in specific sectors, consisting of seismic workers, to wear flame-resistant clothing," Bednarik says.
As part of the clothing program, the business includes up to 10,000 stitches of needlework in its pricing. The company also makes headwear from the special material. Stutts discovered that the team can stitch it making use of regular production techniques, offering even more orders to maintain the embroidery devices running constantly. The business also began a brand-new website,, that features the item.
Revitalized by the significant progress the company has actually made in current months, Bednarik and also Eavenson eagerly anticipate implementing prepare for additional growth. Initially, they intend to boost its online existence and also probably launch a line of themed caps. American Made Cap Co. still takes part in a give program that can assist provide funds to raise its Internet presence as well as advertising in general. They additionally want to create a program with a significant account to generate caps for supply throughout sluggish times.
Bednarik wishes to fill the plant's manufacturing ability and start a new, better reward program for workers. "I would certainly rather pass even more cash to the employees if I can jam this place with quantity," he says.


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