Pioneer Equipment Co. experienced a significant expansion in the summer of 1998 with the construction of a new barn on their property. Demonstrating an understanding of their workforce and local traditions, this new structure included a dedicated section on the west end specifically designed for employees arriving to work via horse and buggy.
Construction of Pioneer Equipment Co.'s new barn in 1998, featuring horse and buggy parking for employees.
As the new millennium dawned, Pioneer Equipment Co. continued its trajectory of success. This period was marked by the introduction of numerous new products, showcasing the company’s commitment to innovation, although some of these product lines were eventually discontinued as market demands evolved.
By 2007, the facilities of Pioneer Equipment Co. were once again feeling constrained by the company’s rapid growth. The Wengerd family, at the helm of Pioneer Equipment Co., initiated discussions about expansion options, considering both physical additions to their existing buildings and the possibility of constructing entirely new facilities. This period of deliberation involved critical questions about the desired scale of infrastructure, the sustainability of continued growth, and strategic decisions regarding product lines. Furthermore, the family carefully considered their responsibilities in managing resources, guided by their principles.
A pivotal moment arrived at their year-end review in 2008 when their accountant introduced them to the principles of Lean Manufacturing. Lean Manufacturing, a methodology focused on maximizing efficiency by minimizing waste across all stages of production – from order placement to revenue collection – resonated with the Wengerd family and the leadership team at Pioneer Equipment Co. Following consultations with their supervisors, Pioneer Equipment Co. made the strategic decision to implement Lean Manufacturing principles in the fall of 2008.
The adoption of Lean Manufacturing had a transformative impact on Pioneer Equipment Co.’s operations. By streamlining processes and eliminating inefficiencies, they achieved a remarkable reduction of over 50% in their work-in-process inventory. Additionally, their finished product inventory decreased by nearly 25%. This operational overhaul unexpectedly created significant space within their existing manufacturing building, effectively alleviating the previously felt constraints. The newfound efficiency allowed Pioneer Equipment Co. to offer customers significantly shorter lead times, a crucial competitive advantage. This strategic shift facilitated substantial growth for Pioneer Equipment Co. without requiring immediate physical expansion.
The employees of Pioneer Equipment Co. played a crucial role in the successful implementation of Lean Manufacturing. Empowered by their training, the team proactively sought solutions to optimize processes, often exceeding the limitations of readily available tools and equipment. This ingenuity led to the in-house development of solutions like metal pegboards and mobile workstations, designed to address specific workplace challenges. These internally developed solutions marked the genesis of Flextur, a product line that has since become a cornerstone of Pioneer Equipment Co.’s diverse offerings.
Throughout this period of growth and innovation, the primary manufacturing operations of Pioneer Equipment Co. remained concentrated in their 145’ x 200’ building. However, to optimize production and leverage local expertise, certain components such as cushions, wood tongues, aluminum seats, and plow handles were outsourced to other family-owned businesses in the vicinity, fostering collaboration within the local business community.
In mid-summer 2013, John Wengerd, a fifth-generation family member and shareholder in Pioneer Equipment Co., acquired a picturesque property along the Sugar Creek in Sonnenburg Valley. Following his marriage to Ina Weaver, Pioneer Equipment Co.’s long-time secretary, John established his residence on the property later that summer. In the spring of 2014, John and Ina undertook the renovation of a vacant veal barn on their property, transforming it into a functional manufacturing facility. This expansion raised the strategic question of which segment of Pioneer Equipment Co.’s manufacturing operations would be best suited for this new location.
Driven by a continuous pursuit of manufacturing excellence, the Wengerd family explored advanced technologies to further enhance efficiency. Their research led them to laser cutting technology, recognizing its potential to improve equipment design through the creation of precisely shaped plates that could add structural strength exactly where needed.
After thorough evaluation and strategic planning, Pioneer Equipment Co. decided to invest in a used Mazak laser plate burning machine. This substantial piece of equipment, weighing over 18,000 lbs., was delivered in mid-July 2015. By late August, the refurbishment, installation, and setup of the Mazak laser were completed. In early September 2015, production officially commenced at Pioneer Equipment Co.’s PLANT 2 location in John’s shop, situated approximately five miles from the main facility, marking another significant milestone in the company’s ongoing expansion and commitment to innovation.
