Managing a major facility expansion while maintaining full-scale production requires meticulous planning and executed strategy. Throughout the construction of Bison Inc.’s new 85,000+ square foot facility addition, a dedicated 17-member warehouse and shipping team successfully protected the company’s supply chain—delivering 100% on-time order fulfillment without a single construction-related product hold.
Under the leadership of Site Manager Arman Ebrahimi and Chief Operating Officer JC Stiles, Bison developed and executed a strategic six-phase supply continuity plan designed to shield dealers and institutional customers from construction disruptions.
Strategic Risk Mitigation: The Six-Phase Supply Plan
When groundwork began, physical work areas in the packaging and shipping departments were significantly constrained. To prevent inventory bottlenecks, Ebrahimi’s team proactively initiated a staged inventory strategy months before construction crews broke ground.
Key Operational Milestones Included:
- Predictive Inventory Stockpiling: Starting in mid-January, the packaging department analyzed historical sales data to pre-package and stockpile high-volume, core SKU items ahead of physical space reductions.
- Zero Downtime Execution: Despite active construction across major staging areas, the team maintained continuous daily production and shipping schedules.
- Buffer Management for Inter-Facility Transitions: As operations prepare to consolidate into the unified facility footprint, the logistics team is replicating these inventory buffer phases to ensure seamless department-by-department relocations.
"Our priority was making sure our customers' timelines were never impacted by our facility growth," explains Arman Ebrahimi, Site Manager. "I’m incredibly proud that we didn’t put a single product on hold due to construction, nor did we lose production time. That level of reliability is only possible when you have total teamwork between management and floor staff."
Future-Proofing Workflow Under One Roof
Prior to the expansion, managing material transfers between separate departmental locations required extra logistics coordination. Unifying fabrication, coating, packaging, and shipping under a single roof permanently optimizes Bison’s internal workflow:
- Accelerated Inter-Departmental Transfers: Direct line-of-sight routing from primary assembly and safety padding to final packaging.
- Enhanced Lead-Time Reliability: Streamlined loading docks and re-engineered high-density pallet racking to process high-volume freight faster during peak seasonal periods.
- Improved Quality Control: Centralized staging allows for final multi-point quality inspections before freight loading.
Leadership Profile: Driven by Dedication and Growth
The success of Bison’s logistics operations reflects the deep experience of its team leaders. Arman Ebrahimi joined Bison in 2016, building a versatile career through hands-on technical roles—advancing from portable system assembler to Backboard Department Supervisor, Packaging & Shipping Supervisor, and ultimately Site Manager.
After a brief venture running his own business in 2022, Ebrahimi returned to Bison in late 2023, drawn back by the company's strong culture and workforce community.
"I care deeply about my team at Bison—they truly feel like a second family," says Ebrahimi, whose father, Behrouz, also works at the company and was recently named a Bison Employee of the Year. Outside of managing facility operations, Ebrahimi spends his free time with his wife, Mahroo, their young son, Aaron, and his extended family.
Dependable Manufacturing and Supply Chain Support
For athletic directors, school boards, and park officials, equipment delivery timelines are critical to project completion. Bison’s commitment to operational planning ensures that facility upgrades stay on schedule from order placement to final delivery.
To learn more about Bison’s domestic manufacturing capabilities or to check lead times for upcoming facility projects, visit bisoninc.com or contact your regional sales representative.