Based on a puck system, fixtures and
universal hardware provide flexibility, while
wood and bamboo soften the environment
with natural notes.
Leggett facilities that could produce the
highest quality product at the lowest possible price within the given time frame. As a
result, the majority of the project, about 90
percent of the metal fixtures, was placed at
Leggett’s China Fixtures in Kunshan City,
Jiangsu, resulting in a significant cost savings for Performance. The balance of the
fixtures, including all millwork, was produced at two Leggett U. S. locations.
As Hilyard notes, the blend of import and
domestic manufacturing was necessary to
meet the company’s store model requirements. “It was critical that we lowered our
build-out cost to meet the financial model,”
he says. He cites additional benefits as well.
“The manufacturing blend allowed us to
test initiatives with domestic production
and eventually move to import for rollout,”
he says. Lowering overall fixturing costs
also allowed the retailer to introduce new
visual and interactive programs.
Hilyard and members of his team
traveled to Leggett’s plant in China and
reviewed prototypes there, working closely
with Leggett project directors and engineers there to fine-tune the design and
in Leggett’s facility—and were able very
quickly to see the results of our changes.”
Hilyard estimates that the prototyping
process reduced the timeline of the project
by months. Leggett and Performance also
created a phasing plan to efficiently implement any further design changes that
for installation. Ultimately, production
required 12 weeks, and ocean shipping
added an additional four weeks.
Performance Bicycle opened 14 stores
with the new design in 2011 and relocated
t wo more. Hilyard says that response to the
new design has been overwhelmingly positive from both store operators and guests.
“This has to be one of the most efficient
ways to work through the prototyping process,” Hilyard notes. “We reviewed between
50 and 75 unique fixtures and parts there
Once completed, the imported fixturing
was shipped by ocean freight, consolidated
with the domestic product, and delivered
to the individual Performance Bicycle sites
Plans for 2012 will likely include additional relocations and expansions, as well
as integrating elements from the new
design into existing locations.