2021 Proves to be Challenging for Bicycle Builders

A bicycle is made up of hundreds of individual parts. With all of the options that people choose from today, It is impossible for a custom builder to stock everything. At least half of the parts for most new bikes have to be ordered after the bike is put into our queue. This has been the case for several years now. 2021 has posed some big challenges to us custom builders. Here at R+E Cycles, we are working hard to meet those challenges, and to get your bike done as close to the due date as possible. I thought I'd take a minute to tell you all about what custom bike builders like us are facing.

First, a quick trip through history.

In the 1990's through about 2010, we had 3, maybe 4 different configurations of parts for people to choose from. We could predict, and stock about 95% of all the parts that were needed to build the year's bicycles. This meant that we could easily predict when a bicycle would be done. The longest part of building a bicycle was designing, building and painting the frame/fork, and we had complete control of that.

Sooo Many Choices
Then component manufacturers began to offer more and more options. Manufacturing methods shifted to a 'just in time' model, and this allowed for expansion of product offerings. Customers started picking those options. To give you an example of what I'm talking about, in 2010, there were Shimano Ultegra shifters and derailleurs. They were very popular, and we could order 50 or so Ultegra parts kits and have them on hand. Then Shimano began to offer traditional Ultegra shifters/derailleurs AND Ultegra shifters/derailleurs that had electric shifting. Soon, they began to offer Ultegra with standard shifting, but with hydraulic brakes. Then, of course, Ultegra with electric shifting and hydraulic brakes. Each new option is labeled as Shimano Ultegra, but they are actually completely different animals. So now there are 4 different Ultegra shifter styles, and many different Ultegra derailleur options. There's really no way to have them on hand anymore as we don't have the room, or any way to predict what will sell.

This 'exploding' array of options went through the entire Shimano line, and also through SRAM and Campagnolo products as well. Add this to the fact that our industry was already speeding down the road to abandoning all hub, axle, bottom bracket and head set standards (another article) and you've got a very challenging task to build a custom bike. By 2016, there was no way to put together a big parts order that could complete anywhere near 95% of our year's bicycles.

Not to worry though, Shimano and SRAM kept a good supply of parts on hand, and we could order them as we went. White Industries had all of the new head set, axle and freehub designs in their wheel house (pun intended), so these new specifications were a phone call away. We could still order a big supply of the 'common' parts that we use on bikes. For instance, rims, stems, basic hubs, handle bars, seat posts, seats, basic cranks, etc.. But the derailleurs, shifters, and any other specialty items that people chose would have to be ordered after the bike order was finalized. There were just too many options to try to stock these things. This meant that by 2016 we could stock only about 40% of the parts needed to complete most custom bikes.

Ordering evolved into a bigger job, but as long as we ordered the parts for any given bike within 2 weeks of its due date, we would have the parts in time for final assembly and still make our due date easily. It posed a bit of a challenge with storage as we now had to keep more specific parts separate for different bikes. In the past, the assembler would pull the parts from the 'common' parts bins as we started assembly. It was very smooth and efficient. But, all in all, we worked out a system that kept things moving along quite nicely.

Breaking The Supply Chain
Enter 2020 and Covid19. In March 2020, worldwide supply chains were shut down in sporadic fashions around the world. Here in Seattle, we were shut down for 2 months. An industry that had evolved into endless choices, and no standard sizes of anything was not prepared for this. Small manufacturers around the world (sub-contractors) make most of the small parts for the big companies like SRAM and Shimano etc... Small parts that go into shifters, derailleurs, brakes etc. These small guys started dropping like flies, or just throwing in the towel. If 5% of them drop, then that kills the entire line. I can't put 95% of a shifter, or 95% of brake onto a bike.

The chaos resulting from this disruption is something that will be with our industry for at least a few years. In 2021, we're seeing shortages of everything bicycle related. We have changed several things about our business model (and new changes every week). I wanted to draw a picture for you of how the parts for your custom bike are attained in 2021. To deliver a custom bike is more challenging now than it has ever been in my 30+ years in this industry.

After you order your Custom Rodriguez:
In 2021, when a bike is ordered, we immediately begin ordering the parts (usually before you leave the store). I used to be able to order all, or most of the parts from one distributor. Now the warehouses that supply bicycle companies and shops are all empty. So, I order one part at at time, from any number of different vendors. It takes hours to scour vendor site after vendor site looking for parts. I may order the right shifter from a company in Wisconsin, and the left shifter has to come from England. The front derailleur may come from EBAY, and the rear derailleur from Germany. Most likely, a vendor will have just one or two of an item, and they won't have it in 10 minutes, so I have to order it now. Shipping sometimes costs more than the part I'm ordering, but every 'found' part we consider a small miracle.

Ordering used take about 4 - 6 hours per week. Now, ordering takes more like 50 - 60 per week. This supply chain disruption goes through the entire process. From materials to build the frame to things like inner tubes for the repair shop. We can't sell a bicycle without a right shifter, or a chain, or tires, but these are all things that we are scrambling to get...all the way down to spokes.

"So Dan, How's it Going?"
Even with all of this craziness, most of our 2021 Rodriguez bikes have been delivered on or before their estimated due dates. We've designed our production software (yes we write our own software) to track every part for every bike that is in the system, and once a bicycle's parts are all here, or on the way, that bike gets fast tracked. But, in some cases, the parts are several months out. It's a bad idea to build and paint frames that will not be assembled immediately, as they hang around the shop and may get scratched. So, we hold off building and painting those frames until we get word that the the last part is on its way. The good news is, many people are getting their new custom Rodriguez well ahead of schedule. For those who desire parts that take longer to get, there's a bit more waiting time than usual.

So, can I tell you when your desired parts will be available? I'd love to. The parts companies have tried hard to keep us all in the loop, but they have not been able to meet any of their 'expected' dates. I'm hesitant to tell people dates, because Shimano and others keep bumping these dates out longer and longer.

This is for Sure!
What I can tell you is there is not a team in our industry that is working harder to meet their customers' desires and expectations than this team right here at R+E Cycles. We are calling, emailing, and demanding when necessary, the service we need to get your bike done. We have never faced a challenge we didn't whip, and we will whip this one. That being said, I do need to ask for your understanding if we cannot control a situation with a parts manufacturer. Sometimes the only thing we can do is wait.