Reviewing the cap production and embroidery operations 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 and also Rickey Eavenson, who determined to support their local west Texas economy by purchasing American Made Cap Co., a battling cap supplier that had undergone several adjustments in ownership during the past three decades, with numerous workers persevering through the company's rough times. With the new Custom velcro patches local business owner came new wish for the firm, which I had done business with during the "gimmee-cap" boom of the 1970s. Throughout my preliminary check out earlier this year, I recognized several locations for improvement, however the greatest obstacle remained discovering enough clients ready to pay a little bit much more for a premium, American-made cap. Recognizing a corresponding product the company can produce or embellish to generate added income was an additional obstacle. Bednarik disclosed that some essential workers adjustments actually have actually altered the skin of their organization. At the time of my previous visit to American Made Cap Co., new Production Manager David Stutts had simply started collaborating with the firm. Stutts was experienced with manufacturing in a different industry, and also was acquainting himself with the procedure of production as well as decorating headwear. I could distinguish his inquiries that Stutts is a really quick study as well as, as of press time, has obtained a solid grip of all phases of manufacturing. Among the discoveries he made is that during a previous owner's tenure, the embroidery equipment thread trimmers had actually been shut off to boost stitch outcome. This benefitted equipment operators, who got on an incentive program. Not familiar with the embroidery process as well as maker capabilities, this problem was only uncovered after the company paid numerous hrs of overtime to workers executing trimming obligations. Furthermore, a number of various other new staff members are actually making an influence. One has graphic arts abilities and screen printing experience, and is being trained to provide back up to digitizer Wanda Eavenson. Another brand-new staff member is making contributions in the location of infotech and also is being cross-trained for various other responsibilities. Both new staff member additionally follow up on new company leads. Progression on top of the employees chain additionally aided to make changes that improved the staffing in other means. Among the lessons found out by the ownership is that certain workers are not always indispensable. It's a common anxiety amongst company owner and monitoring that everything will certainly quit if one or more essential staff members leave the company. In my experience, nonetheless, this is hardly ever the instance. American Made Cap Co. located that regardless of shedding a number of staff member-- including a manager-- that production was maintained without avoiding a beat. NEW PROCEDURES, BUSINESS By simply observing and making changes to company methods, Eavenson as well as Bednarik have minimized their everyday operation expenses by $500-$ 600 each day. This has significantly improved capital and also can be credited to numerous essential modifications. A large modification is streamlined documentation, which was accomplished by taking a close check out paper circulation within the business and making changes that helped improve performance. Administration also put emphasis on charge card settlements for consumers, which minimized the management expenses connected with invoicing and collection. In the brand-new organization arena, four fascinating and also substantial cap manufacturing chances have actually been introduced to American Made Cap Co. from companies in Colorado, New York, California as well as Texas. At press time, some new accounts were still in the process of being expanded, however the brand-new organization is giving the cash flow needed to produce a healthy and balanced organization profile. One of the new accounts sends its own patterns and also products to American Made Cap Co., which gives cut-and-sew plus embroidery solutions. Keeping the embroidery machines humming adds to paying the overall expenses costs for the plant. One more payment to the business's success is its organization with the Go Texan program, from which it has actually reaped major benefits. Via association with this program, sponsored by the Texas Department of Agriculture, a company's name is associated not just with American-made products, however additionally Texas-made items. It was a special day in July when Texas Department of Agriculture Commissioner Todd Staples visited the firm. He acknowledged American Made Cap Co. for its use material made from American Cotton Growers (based in neighboring Littlefield, Texas) in the company's caps, aprons as well as tote bags. The largest and also most promising advancement the firm has experienced throughout the past couple of months is the addition of a complementary line of product. The item-- lightweight, flame-resistant clothing-- is used extensively by companies with employees in oil and gas areas. These firms likewise utilize great deals of headwear, making sales calls two times as efficient. " It's a perk that the United State government needs workers in certain industries, including seismic workers, to put on flame-resistant garments," Bednarik says. As part of the apparel program, the company consists of up to 10,000 stitches of embroidery in its rates. The firm also makes headwear from the special material. Stutts discovered that the team can embroider it utilizing regular production approaches, offering more orders to maintain the needlework devices running regularly. The company also started a brand-new web site, americanfrc.com, that includes the product. WHAT'S NEXT Rejuvenated by the incredible development the company has actually made in current months, Bednarik and Eavenson eagerly anticipate executing prepare for additional growth. First, they want to boost its online presence and probably initiate a line of themed caps. American Made Cap Co. still takes part in a grant program that can assist give funds to raise its Internet existence as well as marketing as a whole. They additionally want to develop a program with a significant account to produce caps for supply during sluggish times. Bednarik wants to load the plant's production ability as well as begin a new, improved reward program for workers. "I would certainly instead pass even more money to the employees if I can jam this area with volume," he claims.