High-End Bicycle Manufacturer – Velocity Cycles

Velocity Cycles produces custom high-end bicycles using parts sourced from multiple 
international and domestic suppliers. Each bike is unique, with custom frames, components, 
and finishes tailored to individual customer specifications. Previously, parts were tracked 
across multiple spreadsheets, leading to assembly delays, missing components, and 
difficulty in financial tracking.
Assembly lines often experienced bottlenecks because a single missing part could halt 
production. Additionally, labor costs and materials were tracked separately from shipping 
and order management, making it difficult to understand actual profitability per bike. 
Customer orders occasionally missed delivery deadlines, affecting trust and reputation. The 
company also struggled to predict demand for certain bike models, leading to overstock of 
some parts and shortages of others.

FireFlight Solution

Part Inventory Management:FireFlight tracked every component from supplier delivery to assembly, ensuring no parts were misplaced and reducing stockouts.

Assembly Progress Tracking:Each bike’s assembly stages were monitored in real-time, allowing managers to see bottlenecks and adjust schedules proactively.

Cost Tracking & Profitability Analysis:Labor, materials, shipping, and overhead costs were all consolidated per bike, providing accurate margin analysis and supporting pricing decisions.

Customer Order Integration:Bikes were linked to specific orders, ensuring custom specifications were met and deliery timelines adhered to.

Scenario Planning & Demand Forecasting:FireFlight allowed management to simulate changes in part sourcing, assembly schedules, and shipping, helping to optimize workflows and invento y allocation.

Maintenance of Tools & Equipment:Assembly tools and machinery could be tracked and scheduled for maintenance, educing downtime.

Velocity Cycles eliminated assembly delays, minimized part shortages, and  improved customer satisfaction by reliably meeting order specifications.

 Financial insights allowed the company to optimize pricing and maximize profitability per bike. Inventory turnover improved, and the company gained confidence in scaling production without risk of missed deadlines.
“The names of this company has been changed to protect their information, and each scenario represents a practical use case of FireFlight”.