8 studies · USA, Colombia & France

Case Studies

Detailed analysis of visited workshops: production flow, organization, strengths, areas for improvement and key takeaway.

Artisan bicycle manufacturing workshop, CIRCA Cycles, Portland

CIRCA Cycles | High-end aluminum & structural bonding

Artisan manufacturer of custom aluminum bicycles using structural bonding. Pure pull flow, zero finished goods inventory.

Portland, Oregon, United States · Rich Fox

Pull flow CNC machining Custom-built
TIG welding in the workshop, Co-Motion Cycles, Eugene

Co-Motion Cycles | Vertical integration & TIG welding

Rare vertical integration: design, CNC, TIG welding, painting and assembly on a single site. 4-5 bikes/day made to order.

Eugene, Oregon, United States · Dawn Shepard

Vertical integration CNC machining Custom-built
Wheel manufacturing, Rolf Prima, Eugene

Rolf Prima | Break-in process & systematic quality control

High-end wheel manufacturer. 3-cycle break-in process and systematic in-house testing machines.

Eugene, Oregon, United States · Jimmy Krigbaum

Quality control Pull flow R&D
Folding travel bicycle, Bike Friday, Eugene

Bike Friday | Pouch kanban & electrostatic powder coating

Made-to-order folding bikes. Pouch-based kanban system, in-house electrostatic powder coating.

Eugene, Oregon, United States · Fraeda Scholz

Kanban Pull flow Visual management
Precision CNC machining, White Industries, Petaluma

White Industries | Precision CNC & design-to-cost

High-end CNC-machined components. Design-to-cost from conception, zero marketing, 100% word of mouth.

Petaluma, Californie, United States · Sean Walling

CNC machining Design-to-cost Automation
CNC machining workshop, Paragon Machine Works, Richmond

Paragon Machine Works | Frame builder parts & 3D validation

Specialized subcontractor for frame builder parts. Systematic 3D validation before production runs.

Richmond, Californie, United States · Calvin Norstad

CNC machining 3D validation SMED
Logo Scarab Cycles, artisan bicycle maker, El Retiro

Scarab Cycles | Artisan custom steel manufacturing

Artisan custom steel bicycle workshop in the Antioquia mountains. A few bikes per week, full customization, paintings by local tribal artists.

El Retiro, Antioquia, Colombia · Julian Ayala

Welding Steel Custom-built Artisan craft
Logo Origine Cycles, carbon bicycle manufacturer, Valenciennes

Origine Cycles | Industrial customization in pull flow

Industrial customization in pull flow: each bike is configured online, individually painted and assembled to order. 30-35 bikes/day.

Valenciennes, France

Pull flow Custom-built Visual management Made in France

Cross-cutting analysis

Limits & Opportunities

Analysis of structural constraints and development levers observed in the visited workshops and factories.

Read the analysis →
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