Starting Semester: Spring 2024
Assigned: Yes
Location: Gainesville

Fox Factory

Client Profile

Fox Factory designs, engineers, manufactures, and markets suspension products. The company provides performance-defining products such as suspension systems and components, cranks, wheels, cycling components, and other components for bicycles, snowmobiles, on-road and off-road vehicles, trucks, side-by-side vehicles, motorcycles, and other specialty vehicles. Fox also provides products to original equipment manufacturers (OEMs). Fox Factory is headquartered in Duluth, Georgia with operations around the world including a large manufacturing facility in Gainesville, Georgia that produces shocks for off-road power vehicles.

Project Description

Title: Warehouse Material Flow Improvement

The Fox Factory Power Vehicle group has experienced exponential growth over the past several years and started up as a large greenfield factory in early 2020 to accommodate the increased business. Start-up challenges included labor and material shortages amid the outbreak of COVID and the resulting ripple affect to productivity.

Incoming materials at the Gainesville location are warehoused then delivered to assembly lines via kitting and Kanban processes that have been challenged by accelerated growth, high product mix, and complex shock designs. This project will focus on material flow from receiving through the warehouse and into the Kanban and kit locations on the production lines.

Goals / Deliverables:

- Labor balancing

- PIV / pedestrian traffic management

- Develop standard work for kitting and PIV operators

- Sustain inventory accuracy

Impact: Improve Safety, reduce labor, improve uptime, increase space


Process Improvement, data analysis, problem solving, and creative thinking