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The Reshoring Reckoning: Why American Manufacturing Can’t Afford to Wait This One Out

By
Kevin Brecht
March 7, 2025
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Veryable has had the opportunity to work with over 6,000 manufacturing and distribution businesses. We’ve seen operations that hum like well-oiled machines and others held together with duct tape and determination. And right now, we’re watching something happen in American manufacturing that reminds me of what my father used to say about opportunity: “It doesn’t knock twice, and it sure as hell doesn’t wait for you to finish your coffee.”

What’s Really Happening on the Factory Floor

Let me tell you what we’re seeing in manufacturing operations across the country - not what some economists in air-conditioned offices are predicting with their fancy algorithms.

Those 25% tariffs on Mexico and Canada? That 20% bump on Chinese imports? They may be temporary. They may be political theater. What they truly signify is the beginning of the biggest reshuffling of manufacturing in our lifetime. And even if are just a ploy, they show us just how crippling it can be to find yourself reliant on extended supply chains that can be susceptible to the whims of geopolitical conditions.

And here’s the unvarnished truth that you won’t hear on the news: Many operations are completely unprepared. They’ve been coasting on economic forecasts that never matched what was actually happening on their shop floors. They’re carrying way too many full-time folks while simultaneously having zero flexibility when a big order lands on their desk.

It’s like watching someone wear both a belt and suspenders but their pants are still falling down.

Two Paths Forward - Only One Leads to Survival

There are usually two ways to do something - the right way and the hard way. But in this case, there’s the smart way and the way that puts you out of business.

The “We’ve Always Done it This Way” Path

Some operations are going to stick with what they know:

  • They’ll keep the same fixed workforce that can’t flex up when opportunity knocks
  • They’ll keep turning down orders because they can’t deliver on time…. Or they’ll take the order and deliver late damaging customer relationships
  • They’ll keep paying through the nose for overtime when things get busy
  • They’ll keep carrying folks they don’t need when things slow down
  • And they’ll watch as more nimble competitors eat their lunch

This isn’t theoretical. I’ve talked to operations managers who are already seeing it happen. One told me, “Kevin, we had to pass on a contract that would’ve doubled our business because we had to lay off half our workforce at the end of last year and couldn’t staff up fast enough without destroying our margins.”

The “Let’s Actually Solve the Problem” Path

Then there are the operations adapting to this new reality:

  • They’re building capacity off of their payroll in a new way that enables them the ability to instantly scale up or down with demand
  • They’re saying “yes” to opportunities others can’t handle
  • They’re delivering on time without breaking the bank on overtime
  • They’re letting go of fixed costs and avoiding variable costs when demand dips and avoiding painful layoffs
  • And they’re gaining market share while others scramble to keep up

Embracing the Change

I’m not one to sugar-coat things. Building this kind of operational flexibility doesn’t seem easy (but it is) and it doesn’t happen overnight. It takes:

1. Honest Assessment: Taking a clear-eyed look at your operation and admitting where the inefficiencies are

2. Smart Planning: Building systems that let you expand and contract capacity based on what’s actually happening, not what you hope will happen

3. Practical Training: Making sure your supervisors know how to manage a more dynamic workforce effectively

4. Proper Tools: Implementing technology that gives you visibility and control without requiring an engineering degree to operate (don’t worry we have that tool too with our Workforce Management software)

The operations that get this right aren’t necessarily the biggest or the ones with the fanciest equipment. They’re the ones willing to change “the way we’ve always done it” and embrace a more practical approach to getting work done.

What My Experience in Manufacturing Has Taught Me

I’ve spent years working with manufacturing operations. I’ve walked floors of hundreds of plants and warehouses, seeing first hand what works and what doesn’t. One thing becomes clear: manufacturing leaders are problem solvers at heart. You figure out how to make things work with what you’ve got.

But this reshoring wave isn’t a problem you can weld back together or patch with spare parts. It’s a fundamental shift that requires rethinking how we approach operations and workforce management.

The companies that thrive won’t be the ones with the most resources - they’ll be the ones who adapt faster to this new reality.

There’s an old saying in manufacturing: “If you’re not moving forward, you’re falling behind.” Well, in today’s environment, if you’re standing still, you’re not just falling behind - you’re setting yourself up to be left behind permanently.

The window to get this right isn’t going to stay open forever. As reshoring accelerates, the advantages will go to those who’ve already built the operational muscle to handle it.

The Right Tool for the Job

At Veryable we’ve seen operations completely transform their ability to respond to market opportunities. What Veryable offers may seem complicated…it’s not. We’ve simply built a marketplace that enables manufacturers to scale capacity up and down in real-time and it’s become a game changer for operations facing today’s challenges.

We’ve watched businesses go from turning down orders because they couldn’t deliver on-time, to confidently taking on new customers because they knew they could scale their capacity without breaking the bank. We’ve seen operations that used to bleed money on overtime strategically regain control over their margins.

What makes Veryable different is that we built it specifically for manufacturing and distribution operations. Every feature, every capability comes from real-world manufacturing experience and challenges. This isn’t some generic workforce solution trying to adapt to manufacturing - it’s purpose-built for the way your operation actually works.

If you’re serious about positioning your operation to capitalize on the reshoring wave rather than getting crushed by it, we should talk. Let one of us at Veryable show you exactly how to build the operational flexibility you need to thrive in this new manufacturing reality.

Manufacturing is coming home to America. The question is: will your operation be ready to answer the door when opportunity knocks?

The future belongs to operations that adapt now. Are you going to roll up your sleeves and do what needs to be done?

To get started with Veryable, contact our team of operations strategists or create your free business profile.

To learn more about how Veryable can help you navigate the uncertainty of 2025 and beyond, check out our "Navigating Trump 2.0" page.

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Kevin Brecht
As General Manager of Veryable's Ohio Region, Kevin Brecht brings over 14 years of extensive cross-functional leadership experience in manufacturing and supply chain operations. His proven track record includes implementing lean methodologies that optimized operational processes while leading market entry initiatives. Kevin has experience leading teams across sales, marketing, product, and technology functions. With a passion for economics, and expertise in continuous improvement initiatives, Kevin is focused on operational excellence and market expansion in Ohio's manufacturing and logistics sectors.

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