By Mike Demos, OpExChange Coordinator for the SCMEP
A Unique Manufacturer with Operational Insight
On April 1, 2025, TICO Manufacturing in Ridgeland, South Carolina, opened its doors to the OpExChange network for a powerful benchmarking event. TICO (Terminal Investment Corporation), headquartered in Savannah, Georgia, is a leading manufacturer of terminal tractors—commonly referred to as yard trucks or spotters. What sets TICO apart is its unique dual role as both a manufacturer and operator of these vehicles, giving it a practical understanding of what makes equipment reliable, efficient, and user-friendly.
Their Ridgeland facility is home to the Pro-Spotter product line, including the fully electric Pro-Spotter introduced in 2023 through a partnership with Volvo Penta. TICO also provides terminal services across ports in the Southeast and Gulf Coast, offering tractors and trailers through flexible lease and rental pools.
A Strong Turnout and Warm Welcome
The event attracted OpExChange representatives from 18 companies across 11 counties in South Carolina, eager to explore how TICO has successfully blended lean manufacturing principles with digital innovation. The session began with a networking lunch, followed by presentations to frame the company’s story and strategic initiatives.
Senior Director Daryl Berryman provided a historical overview of TICO’s evolution since the 1940s. He described the company’s early days in transportation, their game-changing introduction of terminal tractor rental pools in the 1970s, and the eventual move into manufacturing in the 1980s.
Digital Solutions on a Budget
Mike Rousch, TICO’s Director of Manufacturing, led the technical presentation and plant tour. His talk centered on the digital tools and systems they have implemented to drive productivity and quality – without breaking the bank. Attendees were struck by the sophistication of these solutions and how TICO had achieved them with modest investment.
One of the standout tools is Tulip, a flexible Manufacturing Execution System (MES) that has become the backbone of many of their digital initiatives. TICO used Tulip to simplify work processes, support operators with real-time information, and eliminate potential errors.
Lean Transformation with SCMEP
A few years ago, TICO set an ambitious goal: to double production output without increasing headcount. They enlisted the help of the South Carolina Manufacturing Extension Partnership (SCMEP), particularly Process Improvement Coach David Woods, to support the journey.
With SCMEP’s guidance, TICO restructured their factory around a sequential build line, moved material storage line-side to minimize travel time, and eliminated waste. The results were transformative. They not only met their goal of doubling output but were also recognized with the 2023 Transformational and Operational Excellence Award from Governor Henry McMaster.
“This took a lot of teamwork,” said Mike. “We couldn’t have done this without the help of SCMEP.”
Smart Tech in Action: Tour Highlights
The plant tour was packed with digital innovations that left the group energized. Among the most impressive:
- QR Vision System: Each truck is marked with a QR code that’s read by an overhead camera at every workstation. The system automatically pulls up work instructions tailored to that truck and task. This not only streamlines the process but also mistake-proofs it – an example of poka-yoke in action.
- Pick-to-Light Technology: Integrated with Tulip, this system helps operators locate parts by illuminating the correct bins with green LEDs – reducing search time and errors.
- Fluid Fill Verification System: At the fluid station, vision cameras and jig detectors ensure that each fluid nozzle is positioned over the correct tank. A green light confirms correct placement; a red light alerts if it’s incorrect – preventing costly fill errors.
- Uptime Center: This dedicated control center is where TICO leadership meets twice daily to monitor performance and align priorities. Four large monitors display live dashboards from the Tulip system. One screen shows real-time fuel tank levels and forecasts when tanks will run out –crucial for planning and ordering. Another dashboard shows the live status of every truck on the floor and their progress, along with a forecast of the next day’s production. The team also uses this room to review material requests and ensure flow stays uninterrupted.
Feedback and Reflections
After the tour, attendees gathered for the customary “Plus/Delta” feedback session. The group was overwhelmingly impressed with the practical and effective use of digital technology. Many noted that TICO’s implementation of Tulip as the digital backbone offered a great model for scalable digital transformation.
There was robust discussion about future improvement opportunities and how other members could apply similar practices at their own facilities. Mike shared a valuable piece of advice as the session wrapped up: “There are hundreds of improvements I want to make, but I’ve learned not to implement too many at once.”
A Model of Practical Innovation
TICO’s story is a testament to what’s possible when a company embraces lean thinking, engages its workforce, and smartly leverages technology. Their willingness to share openly and authentically with the OpExChange community made this visit an inspiring and high-impact experience. As one attendee put it, “TICO didn’t just talk about improvement – they showed us what it looks like in action.”
About TICO
TICO, with corporate headquarters in Savannah, Georgia, and manufacturing operations in Ridgeland, South Carolina, is a leading manufacturer of terminal tractors and a trusted provider of fleet services across North America. The Ridgeland facility plays a vital role in designing, assembling, and supporting the specialized vehicles that keep ports, distribution centers, and industrial sites operating efficiently. With deep roots in the logistics industry, TICO brings decades of operational experience and customer insight to every vehicle it builds. The company is known for its rugged, reliable equipment and commitment to innovation, safety, and continuous improvement. https://ticotractors.com/
About OpExChange
The OpExChange, an SCMEP program, is a peer-to-peer network of manufacturers and distributors in South Carolina known for generating success for members through benchmarking and best practice sharing. Member companies host events and share practical examples of industrial automation, lean manufacturing improvements, and leadership development. It is an invaluable resource to South Carolina companies that provides access to others who are on similar improvement journeys. If your company is interested in participating in this collaborative effort to improve both the competitiveness of your operation and South Carolina, contact Mike Demos (mdemos@scmep.org). More information and upcoming plant visits are available on the OpExChange website www.OpExChange.com.
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