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HPmag | Magazine | Spring 2004 | Industry Profile

industry profile

Any Day, Any Time
By offering 13,000 different building products, chances are Ashley Aluminum has what you need when you need it.


HP: Please give a brief description of your company and its history.

Dave Foushee, Vice President of Sales and Business Development: Ashley started out in Tampa in 1960 as a small, one-branch operation specializing in building materials for pool and patio enclosures—extrusions, screens and the like—and a few years later we expanded to a second branch located in Largo, FL, that specialized in manufacturing roofing pans.

Florida was really booming at the time, so it was a logical progression for us to open more branches up and down the west coast and then over on the east coast of Florida as we moved into the 1970s. At the time, all of our branches were set up as both distributors and manufacturers of building products, and we’ve continued with that operating strategy to this day.

Our customers are primarily building contractors and subcontractors. Like most distributors serving this market segment, your customers come to you one day and ask if you can do this or get that for them, so as we moved into the 1980s we began to expand our product mix to include more diverse aluminum building products such as soffit, drip edge and fascia. We then started a branch that specialized in industrial metals distribution for all types of manufacturers, and at the time we also had another facility in Fort Lauderdale that specialized in design and manufacture of storefront windows and doors.

We had and still have a pretty diverse product mix to serve our customers, and we kept up the growth and diversification by asking, “What are all the different things you can do with aluminum?”

The ’80s and ’90s were periods of tremendous growth for Ashley. We went from being a local company serving Florida to a regional distributor with branches in 11 states throughout the southeast and Texas. We went from a private company to a public company, back to private and then back to public again, and then in 2000 we again went back to being a private company.

Today we are a part of Guardian Industries, specifically the Guardian Building Products Group—the largest wholesale building products distributor in North America. The last branch Ashley opened was number 71 in Ft. Mill, SC, to serve the Charlotte regional area, and that brings us up to about 900,000 square feet of manufacturing and distribution space.

While we have certainly changed and grown over the years our business purpose has remained focused on three things: service, service and more service. We like to think we are pretty good at what we do, but our 400 employees are always striving to do what we do better.

HP: How does Ashley support the hurricane protection market?

Foushee:
Hurricane protection did not start out to be a significant part of our business until Hurricane Andrew, but Andrew obviously changed a lot of things in Florida.

We started out by providing our customers a line of standard aluminum storm panels tolled by another manufacturer, but quickly discovered that our customers in this market require another level of service: I-need-it-this-afternoon service. We were used to providing this level of service to our roofing panel customers, but recognized that if we were going to get there for storm protection we had to be in the business of manufacturing products ourselves. So, we made some substantial investments in machinery and set up a two-pronged distribution network to serve our customers.

We have storm panel tolling machinery in place at our main manufacturing facility in Tampa where we fabricate panels in both standard and custom lengths. If time is not an issue we can turn around an order and get it anywhere within Florida in a matter of days. Where time is more critical, we have set up storm panel cut and punch machines at nine of our main branch locations strategically located around Florida, and they literally can get a custom order done in a few hours. They can do this by taking a 20-foot panel manufactured here in Tampa—which all of our main branches keep in stock—and cutting it down into any length panel the customer may need.

Of course, all of the panel products we offer, which include aluminum, galvanized steel and polycarbonate materials, are tested and certified to meet every statewide code requirement. Our branches also stock pre-cut storm panels in a variety of lengths based upon common window sizes in their particular market areas.

A little later we concluded that we could not adequately serve our customers with storm panels alone, so we expanded our product mix in the late ’90s to include lines of accordion, roll-up, Bahama and Colonial shutters. Our niche in this market used to be to stock and sell extrusions and components for approved shutter systems to manufacturers of accordion, roll-up and Bahama shutters. We still do this, but in the recent past we expanded this focus when we initiated design and development of our own accordion shutter system.

Our system, which we plan to roll out under the trademark International Accordion Shutter, successfully completed all required testing and is currently being evaluated by the folks in Dade County. We also distribute a variety of impact-resistant window and door products, but we are not engaged in any manufacturing activities in this area.

HP: Who are your customers, and what areas of the country do you service?

Foushee: Wow. It’s hard to come up with a short answer to that question because our customer base is so broad. I’d have to say that the majority of our customers have some relationship to the building and construction industry as a contractor or subcontractor. Our building product mix includes virtually everything you would need to construct or finish the inside or outside of a dwelling, so contractors and subs who do those sorts of things are our customers.

Our industrial customers are primarily manufacturers of some metal product—everything from signs to vehicles, to machinery, boats and even satellite communication vehicles to name a few. In the last couple of years we internally developed a new Technical Services Division to provide engineering and technical consulting services for the industry, and we brought some completely new customers to our door: architects, other engineers, developers and some government agencies. Believe me, the list is pretty broad.

Ashley primarily serves a regional area: the southeastern United States and going as far west as Texas. At the same time, one of the really interesting things about being part of one of the largest private multi-national companies in the world, and the largest wholesale building products distributor in North America, is coming to appreciate that our markets are really unlimited. We have some things in the works with other parts of the Guardian Building Products Group where they are looking at distributing some products we manufacture and we are looking at distributing some products they manufacture.

Here in Florida, Ashley has 40 distribution centers to serve every square inch of the state.

HP: What do you believe distinguishes Ashley from its competitors?

Foushee:
Our employees, and the one-stop level of service we are capable of providing for our customers.

When you look at Ashley and our competitors, we all distribute similar products and serve pretty much the same customers. We carry over 13,000 different building products at last count, so we believe our product mix may be a little bit deeper and a little bit broader than most of our competitors. We want our customers to be able to come in any day at any time and get everything they need to complete their jobs at one time. One-stop shopping. If a customer calls in at 5 p.m. and needs a job site delivery the next day at 7 a.m. we want to be able to service him.

The only way you can manage this is by having inventory breath and depth—we stock it so our customers do not have to—and by having excellent employees who believe in and are capable of fulfilling our service mission. We are very fortunate to have both.

I think another thing that is beginning to distinguish us is our vertical integration as a company. More than 20 percent of the products we sell to our customers are also manufactured by us, so—and especially over the last few years—we’ve grown from being mostly a distributor of building products to being a manufacturer and distributor of building products.

I also think our Technical Services Division provides our customers an additional dimension of service for their project requirements. Building codes and requirements in Florida have been evolving over the last few years and it has been difficult for many of our customers to keep up with some of the changes being implemented by their local building departments.

Our Technical Services Department is in business to help our customers in this area. For example, a customer may come to us with his concept for a custom pool cage that has literally been scratched out on the back of a napkin. Technical Services can take that concept and flesh it out into a detailed design and materials list, and provide a set of sealed engineering drawings. The customer is assured that the finished design meets all applicable building codes, and he can also use the sealed drawing package to obtain a permit from his local building department.

We also conduct technical and continuing education seminars around the state about once every quarter on topics of interest to most everyone in the building construction industry. Had one not too long ago specifically on the topic of storm protection.

Ashley Aluminum, LLC
5120 West Clifton Street
Tampa, FL 33634
(800) 749-4067
fax: (813) 884-0255
e-mail: davidfoushee@GuardX.com


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