Bret Boyd on What Mid-Market Manufacturers Actually Need: Capital, Customers, and Options

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Overview

In this episode of Manufacturing Happy Hour, host Chris Luecke talks with Bret Boyd, CEO and co-founder of Sustainment, a company that builds supplier relationship management software for procurement teams. The conversation centers on a survey Sustainment is running with the New American Industrial Alliance (NAIA). Its goal is to find out what is on the minds of the small and mid-sized manufacturers that make up most of the U.S. industrial base.

25 min read

Boyd's central position is that "the combat power in American manufacturing is in entrepreneurial small businesses spread throughout middle America." In their view, anyone serious about reindustrialization has to understand what those businesses are up against. One early finding surprised Boyd: access to capital is coming in ahead of workforce as manufacturers' top concern.

2:31

From West Point to four tours in Iraq

Boyd was a senior at West Point on September 11, 2001. They describe going to the academy for fairly ordinary reasons: free college, a personal challenge, and upward social mobility. That "paradigm changed very quickly," and Boyd's class went directly into the Iraq War.

After graduating in 2002, Boyd branched infantry and served in the 1st Infantry Division and then the 3rd Ranger Battalion, completing four tours in Iraq. They left the service in 2007 and have worked in industry and technology since then. Boyd says the experience "definitely left a stamp" and remains a core part of who they are.

3:39

The military lesson that carried over

Asked what lesson from the military became a strength in industry, Boyd pushed back on the movie image of small-unit leadership, with people yelling orders and demanding obedience "cause I say so." Boyd says this is "absolutely not like that," especially in the special operations community they served in. They describe it as highly competent people working toward a common goal, with "a ton of initiative and creativity," the same qualities Boyd sees in building businesses.

Boyd frames the key lesson as building teams, empowering people to be excellent, and solving complicated problems. They see the same requirements in manufacturing and in company building more broadly.

Boyd also describes themself as "a mission guy." Financial returns and investor interests matter, they say, but what motivates them is working on a problem that is important. Boyd grew up in Fairbanks, Alaska, which they call an oil and gas town. They see manufacturing as "such an important part of the American identity" that they wanted to build a business that helps the industry run more effectively.

4:55

Why supplier relationship management

Luecke asked why, out of all the problems in industry, Boyd chose supplier relationship management (SRM). Boyd describes SRM as the intersection between procurement and supply chain teams at OEMs and large companies on one side, and contract manufacturers and suppliers on the other.

The reasoning rests on the idea that "manufacturing is a team sport" and "gets done in community." Boyd notes that OEMs "can talk about being vertically integrated till the cows come home." Even so, every one of them depends on a trusted network of contract manufacturers and suppliers who are essential to what they sell. Sustainment's aim is to make working across that network easier, faster, more efficient, and to give companies more options.

Luecke tied this to the show's recent episodes on manufacturing in rural and urban communities. In rural areas especially, he said, manufacturing is part of the fabric that holds the community together.

8:40

The "peak globalization" thesis behind the company

Boyd laid out the worldview behind Sustainment. They believe the world has hit "peak globalization" and is moving into a phase defined by more localized manufacturing supply chains. Boyd calls this perhaps a 30- or 50-year secular trend that is only in about its second or third year.

In this view, companies are trying to balance optimizing for cost with optimizing for resilience. Boyd says they see the same push to localize among international companies in other parts of the world.

For American manufacturers, Boyd believes this means the "early innings" of a significant resurgence. They say this is a baseline assumption they discussed with investors when founding the business. Boyd is careful to say this does not mean a return to the 1940s or 1980s. The resurgence will be different and technology-enabled. The broader shift they describe is from a world with one dominant superpower to a competitive landscape where "supply chains are national assets" and "industrial strength is national strength."

Sustainment wants to be part of the infrastructure layer that enables this shift by driving opportunity to U.S. manufacturers. Boyd says this is why the company is a public benefit corporation and why its software is free for suppliers. The business model works like this:

  • Sustainment sells software to procurement teams at Department of Defense organizations and commercial OEMs.
  • The suppliers of those customers tend to join the platform.
  • Sustainment then builds relationships with those suppliers and helps them grow.

The result is that the company engages with tens of thousands of U.S. manufacturing suppliers.

10:52

Partnering with NAIA and the purpose of the survey

Sustainment went looking for "thought partners" who share this view and found the New American Industrial Alliance. Boyd says its CEO, Austin, pronounces the acronym "NIA." Boyd credits the group with representing and stewarding the reindustrialization movement, and mentions its Reindustrialize conference in Detroit in July, which Boyd believes is in its second year.

Boyd draws a clear line: "we're not policy people." Sustainment is not making recommendations to the administration; that is NAIA's core competency. Sustainment's role is to feed NAIA information. Boyd wants to make sure that when "all these fancy DC people" have policy conversations, the actual manufacturers in middle America are represented.

Luecke cited a quote attributed to Sustainment's director of operations, Christopher McCole, from the survey's announcement. It said policymakers often hear from lobbyists and large corporations, while the most authentic, actionable insights come from shop floors, plant managers, and small business owners. Luecke also noted that roughly 98% of U.S. manufacturers have fewer than 500 employees.

On scale, Boyd said the goal is to reach "hundreds working towards thousands" of respondents over time. They acknowledged the difficulty: manufacturers "are not sitting at their computers waiting for you to send them a survey." Sustainment has been working with state support organizations to get responses. Boyd stressed that the survey was still in progress, with results expected around early July.

Boyd explained the focus on small businesses with a figure: manufacturing employs about 13 million people, and roughly 70% of them work in the small business segment. "The rubber hits the road at the small business segment," Boyd said. Supporting reindustrialization therefore means doing things that help those businesses, not just the large companies further up the stack.

14:59

Early finding: capital outranks workforce

Before giving results, Boyd stressed that the cohort analysis is the most interesting part. When responses are broken down by company size and region, similar types of companies report the same problems. For example, the segment of family-owned, second-generation businesses with fewer than 50 employees has its own pattern. Boyd says looking at manufacturing as a whole is harder than looking at these segments, so their generalizations come with that caveat.

Boyd expected workforce to be the overwhelming number-one issue. It is ranking high, and is in the top three almost across the board. But access to capital is coming in higher, which Boyd found surprising.

As they dug into it, the pattern was businesses saying something like: I would enter new markets, but I struggle to access the working capital that lets me take those risks and place those bets. Many put that above workforce on their priority list.

A second finding, not strictly about workforce, also stood out to Boyd. Among companies with fewer than 50 employees, many owners filling out the survey are nearing retirement. A notable number of them did not say they had a clear succession plan. Boyd couldn't recall the exact wording of the question.

Boyd then offered a personal argument: workforce is "downstream" of industry productivity. If more business, revenue, opportunities, and customers flow to mid-market manufacturers, Boyd expects those firms will invest more in advanced technology and capital equipment. They would also hire at more competitive wages, in W-2 jobs with "duration." If the industry is more financially productive, Boyd "suspect[s]" the workers will show up or the jobs will become more compelling. Boyd acknowledged this does not happen overnight.

Luecke said the show often hears that workforce is the top problem, and for many businesses it is. He welcomed the added nuance on capital and succession, noting that succession is coming up more and more on the show.

19:15

The ventilator story: finding hidden capacity

Luecke asked Boyd to retell a story about the early pandemic push to build ventilators. Boyd first explained the problems Sustainment's software and AI address.

On the commercial side, many manufacturers run procurement through Excel and email, often from a single inbox, with no shared source of truth. That makes it hard to be agile, gather multiple quotes, and balance offshore, nearshore, and onshore sourcing. It also creates problems with scaling, risk, and resilience.

On the defense side, Boyd says the supply chain has "attritted over the last 20 years." Many critical items now have a single supplier, and lead times for parts are measured in years. The organizations responsible for equipment like tanks or aircraft are measured on availability, so they end up with poor readiness ratings. Boyd's explanation is a chain of cause and effect:

  1. There are not enough alternative suppliers to create competition.
  2. Without competition, buyers have no leverage over lead times.
  3. Long lead times then drag down equipment readiness.

Sustainment's defense work focuses on technical data packages, meaning the CAD file or a 2D print. From that data, the software infers not only who has built a part before but who could build it. Boyd's example was a not-terribly-complicated repair part for a B-52 at Tinker Air Force Base. In Boyd's telling, thousands of oil and gas manufacturers in the Texas–Oklahoma corridor could make that part. They simply don't know the buyer, and the buyer doesn't know them.

Boyd says the company "really got traction in COVID," working with Texas groups such as the governor's task force on manufacturing and the Manufacturing Extension Partnerships (MEPs) on the ventilator problem. A Google search for companies listing ventilators as a product turned up very few. But when they broke a ventilator's bill of materials into its part groupings, Boyd says there were tens of thousands of Texas manufacturers that could contribute to building one.

Boyd calls this "a really important unlock" for the company and its partners. It showed that the U.S. industrial base should be treated as a resource rich in capacity and capability, as long as you know how to ask and whom to ask.

Boyd emphasized that this is not catalog shopping. A buyer has to identify capable manufacturers, talk to them, and build mutual comfort and a relationship. Then both sides work through a process to get those parts into the end item, whether a ventilator or an airplane.

Boyd connected this back to workforce: it too is ultimately a question of what capability and capacity the industrial base actually has, and how to make the connections between buyers and suppliers faster and smarter.

24:07

Technology outlook: optimistic self-assessments

On technology, Boyd said the survey shows a correlation between access to capital and investment in new technology. They called the two "obviously correlated." Boyd believes many smaller businesses struggle to get competitive financing for working capital, which would make them more comfortable investing. They said this needs more digging and that they didn't have "anything terribly interesting to say there" yet.

Most respondents rated themselves very high when asked how actively they are investing in new equipment, software, technology, and worker training. Almost everyone placed themselves in the upper third of the scale.

Boyd offered two caveats. It might be the psychology of not wanting to tick the box that says the company isn't innovating. And the survey may not have asked the question in the right way.

Still, Boyd said the positive picture matches their own experience. People outside manufacturing often imagine a dilapidated "rust belt" building, but Boyd says the businesses they visit are "amazing," with modern equipment and skilled operators. A tier-four or tier-five supplier facility looks very different from a highly robotized auto assembly line. Even so, Boyd says the number of cobots they see on site visits usually leaves them impressed.

Luecke added that A3, the Association for Advancing Automation, has started tracking cobot sales as a share of robot sales, and the figure is something over 10%.

27:10

Changing how the public sees manufacturing

Luecke raised a recurring theme of the show: manufacturing today is high-tech, but the general public doesn't see it that way. Boyd agreed and tied it to workforce. A high school student who holds the old picture of manufacturing may choose another path. If they knew what the work actually is, they would see "super high-paying jobs working in high-tech" that build deep knowledge and skills transferable across businesses. Boyd thinks telling that story better will bring more people into the industry.

On how to tell it, Boyd pointed to modern media. They said trade publications that insiders read are great. Boyd suspects that shows like this podcast reach a broader, younger, and more relevant audience than what Boyd called, not pejoratively, the industry's legacy media. Video is especially compelling, they said: walk down a production line with an iPhone and people react with "Oh, dang."

Boyd also credited NAIA and similar groups for making manufacturing a national issue. They gave credit to the current administration too. People can argue about whether tariffs are the right policy or how they've been implemented, Boyd said, but manufacturing, reindustrialization, and onshoring are now part of the national conversation in a way they haven't been in years. "I feel like it's happening," Boyd said, "we're moving in the right direction right now."

Luecke, who said he is a couple of years from 40, added a point of his own. It now isn't just people like him and Boyd talking about manufacturing; people aged 22 to 25 are joining the conversation. Middle and high school students may look at someone only five years older and see a path for themselves.

Boyd agreed and noted how many companies now have an executive aged 25 to 30 "following the owner around." Often that role started as "I need to find somebody that understands software" and grew from there. Boyd said they enjoy seeing businesses give real responsibility to people only a few years out of college.

31:55

Procurement outlook: tariffs split respondents

On procurement, Boyd said the survey responses on tariffs are polarized. Respondents say tariffs are either destroying their business or accelerating it, with "nobody in the middle." Boyd again tied this to differences between cohorts.

Boyd spends most of their time with procurement and supply chain teams. They explained why tariffs are especially hard to implement in this industry: it is relational, not transactional. In indirect procurement, such as buying toilet paper, the product is the same from any vendor and only price and timing matter. In direct procurement, a supplier builds parts to the buyer's specification, and those parts go into the buyer's product. Those relationships are deep, and procurement teams have them with international suppliers too.

The challenge is deciding what to onshore, what to nearshore, and where to develop multiple sources. The best practice Boyd sees is a kind of Pareto analysis. Start with the most impactful parts, find alternative sources for those first, and avoid trying "to eat the whole elephant at once."

Boyd stressed how hard planning has become as rates rise and fall and waivers are granted or withdrawn. Their advice to buyers is that this is now "an options game." Develop as many options as possible so you can quickly get multiple quotes as conditions change, because Boyd expects this unsettled interim period to last for the foreseeable future.

Suppliers have a hard time too, Boyd said. New prospective customers ask domestic suppliers for quotes, take them through the qualification process, and then ask whether they can match an international supplier's price. Boyd described the supplier's reaction as frustration at time spent with no chance of meeting that price, because "we pay people 15 times more than they do over there."

Boyd asked listeners to respect the complexity of this moment. If the shift from globalization to localization is real, the period in between "is the hard part." Companies face difficult case-by-case decisions:

  • how hard to lean in,
  • how to align with regulatory and policy changes, and
  • what to invest in now versus later.

In Boyd's experience, most organizations philosophically agree with using industrial policy to grow American manufacturing. Their practical question is how to get from the old world to the new one, and when they will have enough visibility to invest with confidence.

37:04

The levers of industrial policy, and why Boyd says it's about China

Luecke asked Boyd to list the levers of industrial policy beyond tariffs. Boyd named monetary policy, which flows through interest rates and exchange rates and matters greatly for materials and parts. They also named the tools for building critical industries at home: direct capital injection, tax breaks, regulatory reform, and removing barriers to growth.

Boyd then said that "this tariff thing is about China, full stop." They expressed uncertainty about whether "level the playing field" is the right phrase as it's currently used.

Boyd cited an estimate that China will reach 45% to 50% of global manufacturing by 2030. According to Boyd, only two others have reached that level: the U.S. at the end of World War II and the U.K. during the Industrial Revolution. Boyd says China has deliberately invested in and state-sponsored companies in industries it considers important for security, naming shipbuilding, drones, pharmaceuticals, and semiconductors. Boyd says this has made competition very difficult for U.S. manufacturers.

Boyd's example was DJI, which they said has about 90% of the drone market because the Chinese government has put state capital into it for decades. As Boyd tells it, a U.S. drone company competing globally is up against a subsidized rival. The subsidized company wins, captures the economies of scale and giant factories, and the U.S. company goes out of business.

Then, Boyd said, the U.S. finds that small, attritable drones may be "the small arms of the next war," at least according to some lessons emerging from Ukraine, and it can't build them. Boyd presented this as the reason for countering China and for encouraging U.S. industries that lagged during roughly 15 years of Chinese ascendancy.

40:40

Doing it "in an American way"

Boyd argued that the U.S. response has to be different from China's model of giant vertically integrated firms. Their example was BYD, the Chinese electric vehicle maker, which Boyd says has a factory as big as the city of San Francisco. "That's not us," Boyd said. In Boyd's view, Americans are entrepreneurial small businesses. The national challenge is how to "incentivize and encourage and equip and unleash" those businesses to be productive.

Luecke noted that about 85% of the show's listeners are North American manufacturers. He connected Boyd's argument to a recent episode with an MIT professor who studies higher education's role in preparing the workforce and the effects of 40 years of globalization. The key takeaway from that episode, as Luecke recounted it, was that designing products in the U.S. without building them nearby means losing a critical part of manufacturing innovation: design for manufacturing (DFM).

42:37

What manufacturers should do now

Luecke asked what manufacturers should do today to prepare for the next 20 to 30 years. Boyd framed it as deciding "where do you want to be excellent and where do you want to plant your flag."

Boyd's main suggestion was to connect your business with customers in industries that "have to come back" to the U.S. Using oil and gas as an example, Boyd said a shop comfortable with its oil and gas backlog probably has a business that will never go away. But it should ask whether its team, capital equipment, capacity, and skills could serve industries Boyd expects to grow, such as defense and semiconductors. Boyd believes the semiconductor supply chain "in some way, shape, or form is going to have to come back."

Rather than chasing these customers opportunistically, Boyd recommends being "programmatic" about building relationships in them. That is a form of customer diversification, and it connects back to access to capital, investment in people, and advanced technology.

Boyd suggested running the thought experiment of localization actually happening. They clarified that localization won't mean pure onshoring but a blend of onshoring, nearshoring, and some remaining global supply chains. Questions to ask include:

  • Are we positioned to benefit?
  • Could we compete at lower price points?
  • Should we revisit the cost structure of our parts?

Boyd said some respected companies are even considering spinouts. An AS9100 aerospace business that can't go down-market might partner with or acquire a separate company that can compete on lower-tolerance, lower-price work.

Timing is harder. "The right plan executed at the wrong time" doesn't earn much credit, Boyd said. Still, they believe companies that are deliberate and proactive now are doing the right things, compared with those choosing to "hold what I got."

On procurement, Boyd returned to optionality and agility: develop more relationships, more potential sources of supply, and do the work to vet alternatives in advance. Their most important point was about existing domestic suppliers, who Boyd says are being "bombed right now with new inbound customer requests." Boyd advised making sure those suppliers "feel the love." That means visiting the ones you haven't seen in a while and staying top of mind so you remain an important part of their business.

47:09

Navigating the maze of support programs

Luecke's final tactical question was about programs such as MEPs and APEX Accelerators, which help manufacturers work with the Department of Defense. Boyd called this "a really important problem," and one on both sides.

Boyd mentioned new programs the SBA is considering and a Department of Energy program. They admitted they never knew many of these resources existed before entering this business. Boyd knew of the predecessor to the APEX Accelerators before the rebrand but said they don't remember what the old acronym stood for.

Sustainment is trying to aggregate these programs. A supplier who creates a free profile could be matched with relevant programs based on its size, industry, and location. Boyd said this is "not purely wired out" yet.

Boyd's main advice was to start with the MEPs. They consider most of them great organizations and probably "the strongest of all the boots on the ground groups." Boyd noted they are under funding pressure and uncertainty about where they sit within the federal government. Still, Boyd sees them as good gateways to the range of programs available, such as help getting ISO certification and various federal programs.

Boyd acknowledged there are so many programs that it's "candidly hard to keep up." They added that the organizations running them have just as much trouble getting manufacturers to use them, because generating awareness in the community is so difficult.

That is where the substantive conversation ended. The survey results were still incomplete, and the question Boyd raised about how manufacturers will get through the transition was left open. Many manufacturers agree with the direction of industrial policy, but they don't yet have the visibility, or in many cases the capital, to know when to commit.