Top 10 Actionable Reasons to Reshore Production to the USA

Author: Marlin Steel

A Process Engineer’s Guide to Leaner, Faster, More Resilient Manufacturing

For process engineers, reshoring production to the United States is rarely a philosophical decision. It’s driven by measurable outcomes: lead time compression, defect reduction, inventory turns, uptime, and total cost of ownership.

At Marlin Steel, reshoring is enabled through advanced automation, high-tolerance manufacturing, and close engineering collaboration, allowing customers in medical, aerospace, defense, and industrial markets to build leaner, more resilient operations.

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Below are 10 actionable, engineering-focused reasons why reshoring production, particularly with a domestic partner like Marlin, delivers measurable performance gains.

1. Reduce Manufacturing Lead Times by 50–90%

Offshore supply chains often introduce 6–14 weeks of variability due to ocean freight, customs, and long planning cycles.

Marlin’s U.S.-based manufacturing model enables:

  • 1–2 week order-to-delivery cycles for custom wire forms and metal components
  • Rapid scheduling changes without overseas delays
  • Shorter engineering and approval loops

Operational impact: Many Marlin customers reduce safety stock by 30–60%, freeing working capital while improving responsiveness to demand changes.

2. Minimize Defect Escape With Direct Engineering Access

Long-distance suppliers create slow feedback loops that allow manufacturability issues to surface late in production, or worse, in the field.

Marlin provides:

  • Same-day access to manufacturing and process engineers
  • Rapid drawing revisions and prototyping
  • On-site collaboration without international travel

Operational impact: Design-for-manufacturability (DFM) issues are identified within hours rather than months, reducing defect escape risk by more than 80%.

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3. Eliminate the Hidden 10–20% Landed Cost Penalty

Offshore piece pricing often masks significant hidden costs, including:

  • Expediting and air freight
  • Port demurrage and customs delays
  • Rework shipments and tariff exposure

By reshoring with Marlin, manufacturers gain predictable pricing tied to true production costs, not logistics volatility.

Operational impact: Customers often stabilize margins and recover 5–15 percentage points in landed-cost variance.

4. Enable Pull-Based Manufacturing and Demand Agility

Lean manufacturing relies on pull systems and takt alignment—both of which are nearly impossible with long transpacific lead times.

Marlin’s domestic production supports:

  • Weekly or even daily replenishment
  • High-mix, low-volume production without long planning windows
  • Fast response to demand shifts and engineering changes

Operational impact: On-time delivery improves from ~85% to 98–99.5%.

5. Protect Intellectual Property and Tooling

Offshore manufacturing increases exposure to:

  • Tooling duplication
  • Unauthorized “third-shift” production
  • Design and process leakage

Marlin operates under strict U.S. IP protections and provides full audit transparency.

Operational impact: IP-related risk and product leakage are reduced by over 90%.

6. Improve Precision Through Automation and Skilled Labor

Marlin has made significant investments in advanced automation, including:

  • CNC wire bending and forming
  • Robotic and automated welding
  • Laser measurement and statistical process control

These capabilities deliver:

  • Repeatable tolerances of ±0.005–0.015 inches
  • Consistent weld penetration and finish quality
  • Reduced scrap and rework

Operational impact: Many customers experience 20–50% scrap reduction and meaningful quality cost savings.

7. Increase Supply Chain Resilience and Uptime

Global supply chains remain vulnerable to port congestion, labor disruptions, and geopolitical instability.

Marlin’s domestic footprint enables:

  • Short-distance logistics
  • Easier dual-sourcing strategies
  • Lower exposure to global disruption

Operational impact: Supply chain uptime improves from ~92–95% to 99.8% or higher.

8. Simplify Regulatory Compliance, ESG, and Traceability

Manufacturers face increasing pressure around:

  • Material traceability and certifications
  • Labor practices and workplace safety
  • ESG and sustainability reporting

Marlin provides:

  • Full material certifications
  • Documented, auditable production processes
  • A predictable U.S. regulatory environment

Operational impact: Audit and ESG-related risk exposure is reduced by 70–90%.

9. Accelerate New Product Introduction (NPI)

When engineering, manufacturing, and suppliers operate in the same time zone:

  • Validation cycles shorten
  • Prototypes can be iterated within days
  • Tooling and fixture changes happen quickly

Marlin’s engineering-driven approach supports rapid NPI without sacrificing quality.

Operational impact: Time to market is reduced by 20–40%, often translating to millions in revenue acceleration.

10. Lower Total Cost of Ownership Over the Product Lifecycle

Marlin-manufactured wire forms, baskets, fixtures, and material-handling components are built using:

  • Higher-grade steels
  • Robust weld practices
  • Tight inspection standards

This results in:

  • Longer service life
  • Fewer line stoppages
  • Reduced replacement frequency

Operational impact: Downtime decreases by 10–30%, while replacement rates drop by 50% or more.

Why Manufacturers Choose Marlin Steel for Reshoring Initiatives

Marlin Steel is purpose-built for reshoring success, offering:

  • Robotic automation and precision manufacturing
  • High-tolerance, repeatable processes
  • Rapid engineering collaboration
  • High-mix, low-volume flexibility
  • Full material traceability

From a lean manufacturing perspective, Marlin simultaneously attacks muda (waste), mura (unevenness), and muri (overburden), helping manufacturers build faster, more resilient, and more efficient operations.

Reshoring isn’t a trend. It’s an operational advantage, and Marlin helps make it measurable. Contact Us Today!