At A.R.E. Manufacturing, we thrive on solving complex production challenges. So, when Heirloom Roses, a family-owned rose nursery in St. Paul, came to us looking to simplify their supply chain and reduce lead times, we were ready to make it happen.
For years, Heirloom Roses faced obstacles that were holding them back—multiple vendors, lengthy lead times, and a logistical maze. Through a strong partnership and innovative solutions, A.R.E. helped them achieve streamlined operations and faster delivery to their customers. Here’s how we did it.
The Challenges Heirloom Roses Faced
Too Many Vendors, Too Many POs
Before partnering with us, Heirloom Roses worked with multiple vendors to get the components for the custom products that complemented their roses. Every order involved sending purchase orders for raw materials, followed by a series of outsourced processes—welding, powder coating, and laser engraving—before the final product was ready to ship. Managing these moving parts created a logistical headache, and they needed a simpler, more efficient way to keep their production running smoothly.
Extended Lead Times
Juggling all these external processes also resulted in longer lead times. Though their rose plants were ready, the team often found themselves waiting on the additional components, delaying shipments to their customers. Reducing lead times from two weeks to one was a priority, but their current setup wasn’t capable of supporting that. That’s when they reached out to A.R.E. Manufacturing for help.
The A.R.E. Solution: A One-Stop Source for Their Components
When they first contacted our team, Heirloom Roses was looking to consolidate some of their outsourced processes. They knew that our component manufacturing capabilities enabled us to both produce the parts and powder coat them. They were pleasantly surprised to discover that we also had laser engraving capabilities, allowing us to become their one-stop source for the entire product. This not only simplified their supply chain but also allowed them to focus more time and energy on what they do best—growing and delivering beautiful flowers.
Now, with one purchase order, A.R.E. handles everything, from sourcing materials to producing, finishing, and delivering the components directly to Heirloom Roses. The components we manufacture under one roof include:
2-inch round plant tags
Aluminum ground stakes
Sign plates (which are produced by our Tiger Manufacturing students!)
With A.R.E.: Reduced Shipping Lead Times
Once we had gotten into a steady cadence with them, Heirloom Roses expressed another goal: to continue improving their business by reducing their shipping lead times and adopting Lean manufacturing principles. Previously, they only shipped products on specific days of the week, meaning orders placed outside those windows would be delayed until the next scheduled shipping date. To help them overcome this bottleneck, the A.R.E. team leveraged our existing Lean manufacturing practices to accommodate a more flexible approach.
We collaborated closely with Heirloom Roses, ultimately transitioning to daily deliveries. This adjustment allowed them to align their shipping schedules more accurately with customer demand. Instead of waiting for a set day to ship, the team could now promise delivery within a week of the order, accelerating their lead times by days and speeding up their entire production cycle. Our ability to seamlessly flow orders through our Lean manufacturing system meant that we could meet their needs without disrupting our production.
Eventually, our collaboration established an impressive 24-hour turnaround process that is still in place today. Now, when Heirloom Roses receives an order through their website by midnight, they send it to us the following morning. We then process the order, handle all necessary component manufacturing services, and ship it out the very next day. This change has allowed them to ship products to their customers within two to three days, a far cry from their previous two-week lead times!
With A.R.E.: Streamlined Production
To make the process even more efficient, our contacts at Heirloom Roses created a shared spreadsheet that they update whenever they need new shipments. This has led to seamless, real-time order tracking and processing, whereas before we got involved, they were constantly emailing and calling to check on orders from their multiple vendors.
With A.R.E.: Flexibility and Agility in Achieving Higher Volumes
As Heirloom Roses began gaining more traction in the market, their orders grew significantly. When they secured a large retail deal requiring 20,000 parts, the A.R.E. team stepped up to the plate. To meet this increased demand, we utilized our advanced equipment to speed up production significantly. We purchased a second laser engraver and set up a rotary table to process 50 plant tags at once. This additional laser enabled us to handle last-minute rush orders efficiently, meeting their demands and making this year an overwhelming success.
Trust A.R.E. to Help You Achieve Your Goals
The success of the partnership between A.R.E. Manufacturing and Heirloom Roses highlights the value of working with a manufacturing partner who can provide flexibility, efficiency, and personalized solutions. From consolidating their supply chain to reducing lead times and accommodating higher volumes, our long-term partnership ensures their business continues to thrive.
Don’t hesitate to contact A.R.E. Manufacturing to see how we can help you achieve your goals!