U.S. Fence, Don’t fence them in

Manufacturing in Action, Source : The Manufacturer US

U.S. Fence stakes its claim as an industry leader, Brigid Ford reports

Based in Flint, MI, U.S. Fence is the largest manufacturer and distributor of wood and vinyl fencing in North America. While this fact in itself might be impressive, what makes it more so is that it was only four years ago that the company was facing one of the biggest challenges in its history—Chapter 11 bankruptcy.

To turn itself around, U.S. Fence decided to take the opportunity to reinvent itself with a market-based approach. With its sales, marketing, and supply chain groups all located at its Cleveland, OH, headquarters and manufacturing sites in Quebec, Michigan, and Tennessee, the company today is “an independent, aggressive, entrepreneurial company committed to remaining the dominant player in both wood and maintenance-free fencing and railing.”

When it was founded in 1977 as Action Sales & Marketing (it changed its name about five years later), the company focused on pre-built wood fence panels made in Quebec. By the 1980s, U.S. Fence expanded into pressure-treated deck railing, introducing the “Create-A-Rail” line of products, which it still manufactures today. The company boasts that, “Create-A-Rail is a preferred choice by professional deck builders. It is waterproofed to the core, which ensures two seasons of built-in waterproof protection. With the unique handrail system, there are no screws or nails shown, and remodeling existing decks and porch rails is easy.”

In the 1990s an unprecedented demand for maintenance-free fencing and railing fueled growth industry-wide. This, coupled with recent growth in home remodeling, pushed U.S. Fence to develop a wide selection of maintenance-free vinyl fencing and deck railings that never need painting or staining. Today U.S. Fence products are found at major home-improvement centers throughout the country.

U.S. Fence did not limit its evolution to its product line. It made significant investments in improving its manufacturing operations, integrating 5S and lean manufacturing initiatives into its production facilities in Quebec, Michigan, and Tennessee. Much of the focus has been on cross-training, team building, and creating a self-directed workforce.

In addition to looking for ways to improve efficiency and quality, U.S. Fence also invested in creating state-of-the-art facilities. It incorporates robots and machine vision to move a wide variety of fence parts from one end of the line to the other where they are packed, tagged, palletized, and monitored.

One of the clearest indications that U.S. Fence has returned to the industry as a leader is a recent expansion of its manufacturing operations in Bulls Gap, TN. Announced in 2003, this expansion added 120,000 square feet to the facility and, according to local news reports, increased its employment from 350 (when the plant was purchased from Erwin Industries in 2002) to 1,000. All told, the company invested $50 million in construction and equipment and became Hawkins County’s biggest industrial employer.

All of this places U.S. Fence in a solid position for another boom in the industry. According to a report by The Freedonia Group, “demand for fencing products in the US will reach $6.6 billion in 2009, bolstered by nonresidential building construction spending and residential repairs and improvements. Metal fencing will remain the largest material type based on strength in nonresidential uses and ongoing security concerns. Vinyl fencing and concrete panels will grow the fastest.”

Is U.S. Fence ready? Currently the company offers two vinyl fencing product lines: Pro-Series and Pre-Built. According to its Website, the Pro-Series products come in complete, ready-to-assemble kits, are made from durable heavy-duty components, offer aluminum reinforced bottom rails, and can be racked over a varied terrain. The Pre-Built products are pre-assembled, ready-to-install lightweight panels that also can be stepped over a varied terrain. Customers can choose from privacy, semi-privacy, picket, and post-and-rail styles.

Its vinyl line also includes vinyl railing. U.S. Fence contends that “decorative vinyl railing is maintenance free and adds value and aesthetics to any porch or deck. It is available in many styles and all are independently certified to meet major building codes. Vinyl railings are easy to install and will last as long as you own your home.”

U.S. Fence also offers a variety of aluminum fence products. These pre-assembled panels are made from extruded aluminum with a baked-on acrylic finish. The company also offers a limited lifetime warranty, to ensure “against chipping, cracking, and peeling, while still allowing for traditional strength and style.”

Although not included among the “fastest growing” products, wood fencing remains part of the U.S. Fence product line. In its first year of business, U.S. Fence shipped 60 truckloads of the wood fence products. In 2005, it shipped more than 100 times that amount. The company proclaims that “pre-built privacy and semi-privacy panels, along with picket fences, are made from the highest quality wood, and provide the most all-natural style among other fences. Wood fencing using decorative posts adds an elegant design and closure to any home or garden. There are a wide variety of wood species to choose from to add color or grain contrast to the many styles.” Rounding out its offerings are trellises, arbors, and lattice from partner Tuff-Bilt.

While U.S. Fence reaches end-customers primarily through major home-improvement centers, its Website does offer a few helpful features for the do-it-yourselfer. Vinyl and wood fence calculators provide an estimate of how much fencing will be needed for any job. The site also provides installation documentation and step-by-step video clips, from digging a hole to “on center” alignment.

With so much invested in the future, it appears U.S. Fence will meet its commitment to remain the dominant player in both wood and maintenance-free fencing and railing.

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