Tidal New York applies Kanban approach to Reduce Waste and Maximize Value

Tidal New York (also known as Homegrown for Good LLC), whose name reflects a mission to revive American manufacturing, was founded by brothers Tommy and Tim Gibb in 2014. With roots in the footwear industry, the siblings set out to build a company that stood in stark contrast to fast-fashion factories. Tidal’s flip-flops are 100% made in the USA using materials sourced from family-owned businesses, and the company proudly hires military veterans. Known for making the most comfortable flip-flops ever—with a no-questions-asked money-back guarantee—the company operates with a clean, transparent supply chain and a deep commitment to sustainability.

With an emphasis on environmental stewardship, Tidal New York sought to refine its manufacturing processes and eliminate operational waste. MTEC engineer Phil vanOss collaborated with the team to identify inefficiencies not easily visible internally. Value Stream Mapping and process improvements were deployed to help streamline workflow and lay the foundation for a leaner, more efficient operation.

One major upgrade involved the implementation of a Kanban system tied to UPS, allowing inventory to match demand with real-time triggers. Visual management and communication cues were standardized to eliminate waste and maximize throughput—moving from 150 to a projected 400+ flip-flops per day. UPS also took on inserting greeting cards, eliminating a previously manual first step.

Tidal also focused on updating plant layout and reducing curing time. Previously, the same staff often handled strap production and washing. With investment in a continuous-flow washing machine and conveyor system, these steps were uncoupled and greatly accelerated to match the pace of sole and printing operations.

Further improvements included adopting print-to-order processes to reduce inventory, applying a pull-type system, and narrowing color options to further lean out production. While the team still requires more jigs to optimize their second printing machine, the new approach has already triggered substantial change.

As a result, Tidal New York has launched ongoing cost-reduction and continuous improvement strategies, adopted more sustainable production practices, and made meaningful capital investments.