By Mike Demos, OpExChange Coordinator for the SCMEP

In the quiet town of Bamberg, South Carolina, Phoenix Specialty Manufacturing stands as a shining example of American manufacturing resilience. A fourth-generation, family-owned company with roots dating back to 1907, Phoenix was recently honored by the National Institute of Standards and Technology (NIST) as a Hero of American Manufacturing. This well-deserved recognition celebrates not only their innovative spirit and operational excellence but also their unwavering commitment to their employees, their community, and the advancement of U.S. industry.

That commitment was on full display during a recent OpExChange plant visit, where manufacturers from across South Carolina gathered to learn from Phoenix’s impressive lean transformation and operational strategies. The visit offered an inside look at how Phoenix reinvented their plant layout through a ground-up, employee-led initiative that has significantly enhanced safety, productivity, and communication.

A Legacy of Precision and Adaptability

Originally founded in New York, Phoenix relocated to Bamberg in 1967 – a move sparked by a local politician named Ziggy, who convinced owner Robert Hurst Sr. to bring the operation south, famously transporting equipment on watermelon trucks. The company has since grown into one of Bamberg County’s largest employers, providing more than 140 high-quality jobs.

Phoenix manufactures custom precision components – washers, shims, seals, gaskets, spacers, and bracket – for demanding sectors like aerospace, automotive, medical, and defense. All products are made to exact customer specifications, typically within a six-inch outer diameter and from materials as thin as .005 inches. With forty-eight stamping presses, four Swiss machines added in 2024, and a wide array of secondary operations, the company marries legacy craftsmanship with cutting-edge technology.

Their long-standing commitment to quality is evident. Phoenix was among the first U.S. companies to achieve AS certification in the 1990s and maintains complete part traceability. All products are not only made in the USA but are also sourced from American materials – something increasingly rare in modern manufacturing.

Strategic Investments and Lean Implementation

Phoenix’s success is no accident. They’ve continuously invested in advanced manufacturing equipment – CNCs, waterjet cutters, wire EDMs – and built strong internal capabilities, including their own tool and die shop with more than 20,000 dies. They even offer vendor-managed inventory (VMI) programs for clients, keeping safety stock on hand for reliable delivery while helping customers manage costs.

But their most transformative recent investment wasn’t a machine – it was a mindset shift.

Prompted by a candid comment from a key customer who questioned their readiness for future growth, Phoenix launched a bold, multi-phase modernization effort. The initiative began with a $5.5 million expansion, completed in 2022, that unified engineering, quality, and leadership teams into a single location and dramatically improved parking and workflow capacity.

This was followed in 2023 by a $1.5 million complete plant re-layout. What set this project apart was that it wasn’t driven from the top down – but from the factory floor up. Hourly employees, trained in lean principles by the South Carolina Manufacturing Extension Partnership (SCMEP), led the redesign using tools such as SIPOC, 5S, spaghetti diagrams, and Kaizen events. Their ideas were mapped in AutoCAD and visualized with full-scale mockups before being presented to leadership.

Every machine – every piece of equipment – was relocated. Departments were consolidated. Material flow was optimized. Communication and ergonomics improved. Safety protocols were strengthened. And crucially, the workforce was empowered.

Lessons from the Factory Floor

All OpExChange events are rooted in sharing both best practices as well as lessons learned. Phoenix was delighted to share some key takeaways from their year-long transformation with OpExChange members during the visit:

• Employee-Driven Change Works: The people who do the work every day are best equipped to improve it. Utilize and empower this!
• Plan Meticulously: Invest time in the current state. Know and understand your facility down to every outlet and bolt before moving anything.
• Use Visual Tools: Tape mockups and full-scale layouts helped identify real-world spacing issues early.
• Stabilize Change: New layouts were “frozen” for 90 days to allow teams to adapt without constant shifts. This helped to confront inherent resistance to change.
• Communicate Relentlessly: Iteration and transparency were critical to success.
• Dedicate Space for Planning: A “war room” became a hub for collaboration and iteration.
• Prioritize Safety and Support: Change fatigue is real; supporting staff through intense transitions is vital.

The company’s safety enhancements, driven by Maintenance Manager Glenn Earhart and Safety Coordinator Brittany Stroman, were not an afterthought – they were a cornerstone of the redesign.

A Model of Operational Excellence

Phoenix has been a member of the OpExChange for four years and a longtime SCMEP client. Their HR Training and Development Specialist, Todd Jamison, serves on the OpExChange Advisory Board, and their CEO, Russell Hurst, chairs the SCMEP Board of Directors. Their leadership doesn’t just engage – they lead by example.

The OpExChange plant visit drew manufacturing professionals from across the state, eager to learn from Phoenix’s lean journey. The day began with a catered lunch that fostered networking and camaraderie. After presentations, visitors split into teams for guided tours of the newly rearranged facility, where Phoenix associates proudly walked guests through their operations.

One attendee summed up the event in a call the next day: “This is a class organization. Phoenix isn’t doing lean for show – they’re doing what works. It’s genuine, it’s practical, and it’s impressive. The CEO was present but not overpowering. You could see the depth of ownership throughout the team.”

A True Hero of American Manufacturing

Phoenix Specialty Manufacturing is more than a successful business. They are a symbol of what American manufacturing can and should be – innovative, people-centered, quality-focused, and relentlessly forward-looking. Their story is one of generational stewardship, technological excellence, and community commitment.

From sourcing all-American materials to empowering employees with lean tools, Phoenix doesn’t just talk about excellence – they live it. South Carolina is fortunate to have them as a manufacturing leader, and the OpExChange is proud to count them among our most engaged members.

As CEO Russell Hurst put it, “The fourth generation of our family owns the business, and we are actively managing it. We’ve grown, we’re reinvesting, and we are here to stay.” In every sense, Phoenix is a true hero of American manufacturing – building not just parts, but a lasting legacy. A video of their national recognition story can be seen on the NIST YouTube channel.

Reference Section for OpExChange members

All employees at OpExChange Company Sites have full access to the event recap, including videos, pictures, and documentation. If you are a member and need login instructions, contact Mike Demos: mdemos@scmep.org.

About the OpExChange

The OpExChange, a program of the South Carolina Manufacturing Extension Partnership (SCMEP), is the only peer-to-peer network of manufacturers and distributors across South Carolina. For over 23 years, this collaborative group has helped member companies improve performance through benchmarking, best practice sharing, and collective learning. Member companies regularly host site visits and events, offering real-world examples of industrial automation, lean manufacturing initiatives, workforce engagement, and leadership development. It is an invaluable resource for South Carolina manufacturers seeking to learn from others on similar operational excellence journeys.

 

If your company is interested in joining this collaborative effort to strengthen both your operation and South Carolina’s manufacturing community, reach out to Mike Demos at mdemos@scmep.org. Visit www.OpExChange.com for more information on joining and a list of upcoming plant visits.