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Our current lead time for new orders is approximately 22 weeks.
It's beyond stating the obvious that COVID-19 has had a profound impact on the cycling industry. Much of this impact has been positive, with a tremendous surge in new bikes sales and millions of people taking up the sport for the first time. Unfortunately, much of this impact has been challenging as well, particularly when it comes to managing the global supply chains relied on by businesses large and small.
At No. 22, this environment has led to an increase in our lead times over our usual levels, despite our efforts to keep wait times for our bikes as trim as possible. Through 2020 and in early 2021 we hired several key new production staff and have invested in improvements to our space, process, and equipment in order to increase our production capacity in line with substantial growth in orders. Working against these improvements, we have experienced multiple closures of our factory due to state shutdown requirements or positive cases of our staff, staffing challenges as team members require time to isolate or care for impacted family members, and significant disruptions in our parts and materials supply chain.
For complete builds we are experiencing challenges in parts availability: components sourced both domestically and internationally are seeing lead time increases from normal levels of several days to current levels of many months or longer, depending on the component. We are working with our supplier partners to secure early access to components where we can, but parts availability in general remains especially challenging.
Even for frameset orders, many of the same headwinds apply. The list of suppliers for our materials, tooling, equipment, supplies and frame components is surprisingly long and includes suppliers in Europe, North America and Asia. For complex components such as our own carbon fiber forks used on most models, we have seen our production lead times extend from 30 days in early 2020 to over 400 days in mid 2021. Even for supplies as simple as the ceramic "sand" used to blast our frames we have seen lead times extend from days to months from our domestic suppliers.
As a response to this issue we are investing in deeper inventory and ordering key inputs earlier than ever in our history, but the time required to source inputs has exploded and as a result our team is spending substantially more time chasing down items in our supply chain and less time fabricating bikes than normal. We are actively hiring new staff in order to keep our production output steady.
We are working diligently to shrink our lead times back to our normal levels, but in the meantime thank you for your patience. For questions about our lead times, please feel free to contact us directly any time.
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