Ravalli Republic: Darby's Lightfoot Cycles lands new contract for Coaster Pedicabs

Originally published at Ravalli Republic.

June 03, 2014 8:00 am  •  By RUSS LAWRENCE

Lightfoot Cycle’s Rod Miner outside their Darby manufacturing facility.

DARBY – Lightfoot Cycles, which has been building pedal-powered machines from its Darby-area home for more than a decade, landed a contract this past week that owner Rod Miner calls “transformative.”

The contract is with Coaster Pedicabs, a San Francisco-based company that produces pedicabs – three-wheeled, human-powered taxis – and that operates pedicab services in nine U.S. cities. Lightfoot will be building a refined pedicab prototype, based on Coaster’s specifications, which they have simplified for ease of production.

The second phase of the contract involves actually building the machines, possibly in large quantities, beginning this year. The pedicabs will be distributed throughout the U.S., “and eventually internationally,” according to Miner.

Lightfoot is already hiring to expand production, and will be looking into expanding their facility, as well, said Miner. In addition to producing the pedicabs, they plan to continue building their existing line of recumbent bicycles, bikes, and quad-cycles, aimed at a recreational and utility-oriented market.

“We have a new sales manager,” for the existing models, Miner said, “and it’s getting really busy around here.”

The new contract came about through contacts Miner made at an international conference to which he was invited last year, in the Philippines. The Asian Development Bank sponsored the design charla for a new pedicab design, to replace unsafe and inefficient pedicabs in use throughout Asia. When Coaster was looking for product development and manufacturing expertise, one of the other attendees suggested they contact Miner

“It’s a big leap forward in safety, comfort, and visibility,” Miner said of their prototype. “What we’ve done primarily is to simplify it for production.”

The production order will help Lightfoot reach goals that it’s been working toward for years, bringing it to the threshold of effective economies of scale, according to Miner. “It’s pushing us, and we’re learning,” he said, particularly in the area of “lean manufacturing.”

Importantly, it will finally provide the company with a budget for further research and development, to help the company capitalize on its strengths.

Applications for manufacturing positions are currently being taken through the Job Service office in Hamilton.