Pioneer Equipment Company has a rich history marked by continuous growth and adaptation in the equipment manufacturing industry. The late 1990s were a period of significant expansion for Pioneer Equipment, demonstrated by the construction of a new barn in 1998 at their new property. This facility included a dedicated employee section on the west end, specifically designed to accommodate employees arriving for work with horse and buggy, reflecting the company’s heritage and the local community practices.
Construction of a horse and buggy barn at Pioneer Equipment Company in 1998, showcasing early infrastructure development for employees.
As Pioneer Equipment entered the new millennium, their business thrived. They broadened their product range, incorporating numerous new offerings, some of which were eventually discontinued as market demands evolved. This period of diversification highlights Pioneer Equipment Company’s willingness to innovate and experiment to meet customer needs.
Embracing Lean Manufacturing for Enhanced Efficiency
By 2007, Pioneer Equipment’s growth once again pushed the limits of their existing facilities. The Wengerd family, leading Pioneer Equipment Company, initiated discussions about expansion strategies, considering options such as facility additions or even divesting certain product lines. They engaged in deep reflection on their growth trajectory and their responsibilities in managing resources effectively.
A pivotal moment arrived at their year-end review in 2008 when they were introduced to Lean Manufacturing. This methodology, focused on waste elimination across all manufacturing stages, from order placement to cash collection, resonated with their commitment to efficiency. Following consultations with their supervisors, Pioneer Equipment Company wholeheartedly adopted Lean Manufacturing in the fall of 2008.
The implementation of Lean Manufacturing had a transformative impact. Pioneer Equipment successfully reduced their work-in-process inventory by over 50% and finished product inventory by nearly 25%. This dramatic improvement freed up substantial space within their existing building, enabling them to offer customers significantly shorter lead times. This operational enhancement fueled considerable growth for Pioneer Equipment without requiring immediate physical expansion.
The Birth of Flextur: Innovation Driven by Need
The employees of Pioneer Equipment played a crucial role in their Lean journey. Empowered by their training, they proactively sought solutions to improve efficiency. When existing solutions fell short, they began creating their own, leading to the development of metal pegboard and mobile workstations. This in-house innovation marked the inception of Flextur, a product line that has become an integral and vital part of Pioneer Equipment Company’s current offerings.
Throughout this period of transformation, the primary manufacturing operations remained within the 145’ x 200’ main building. However, the production of certain components like cushions, wood tongues, aluminum seats, and plow handles was outsourced to other local family businesses, fostering community partnerships.
Expansion to Plant 2 and Laser Technology Adoption
In mid-2013, John Wengerd, a fifth-generation family member and shareholder, acquired a property in Sonnenburg Valley along Sugar Creek. After marrying Ina Weaver, Pioneer Equipment’s long-time secretary, John established his residence there in the summer of 2014. Subsequently, in the spring of 2014, an existing veal barn on the property was converted into a new manufacturing facility, designated as PLANT 2. This expansion prompted the decision of which part of Pioneer Equipment Company’s manufacturing should be relocated to this new site.
Driven by the ongoing pursuit of manufacturing excellence, Pioneer Equipment explored laser burning technology. They recognized the potential of laser cutting to enhance equipment design by creating precisely shaped plates for targeted reinforcement.
After careful evaluation and planning, Pioneer Equipment decided to invest in a used Mazak Laser plate burning machine. This substantial piece of equipment, weighing over 18,000 lbs., was delivered in July 2015. By late August, refurbishment, installation, and setup were completed. In early September 2015, PLANT 2 officially commenced production, located approximately five miles from the main Pioneer Equipment facility, marking another significant milestone in the growth of Pioneer Equipment Company.
