Vivid Impact

Vivid Impact Scales Production to Meet Monthly Surges Without Increasing Fixed Labor Costs

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“Our industry and customer demand can lead to some very challenging labor demands, and we would not be where we are today without the Veryable platform. We look forward to continuing the growth of our partnership with Veryable for many exciting years to come.”

-Brandon Boyers, EVP & Chief Manufacturing Officer

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Background

Vivid Impact is a leading visual communication and marketing company that has experienced sustained double-digit revenue growth year after year. Originally operating out of two standalone facilities in the Louisville metro area totaling 120,000 square feet, the company expanded its manufacturing capacity through a major acquisition in 2023.

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As the business has grown, Vivid Impact has remained focused on staying at the forefront of technology, lean manufacturing, and innovation. One example of this is PrecisionPop IQ, a patent-pending machine learning platform designed to provide data-driven insights into marketing performance and improve how campaigns are executed and measured.

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This combination of growth and innovation has positioned Vivid Impact to take on increasingly complex and high-volume work.

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Opportunity 

That next phase of growth accelerated when Vivid Impact secured a major contract with a national convenience store chain to produce and distribute monthly promotional kits to more than 7,000 locations across the United States.

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Executing at that scale required a significant increase in production capacity. To support the contract, the company opened a new facility in Mesa, Arizona, expanding its footprint to more than 200,000 square feet across two states.

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However, the primary challenge was not just scale. It was variability.

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Demand for these kits is heavily concentrated in the final two weeks of each month, when production requirements increase sharply. During these periods, labor demand can rise to nearly three times the baseline needed during the rest of the month.

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Traditional approaches to staffing could not effectively support this model. Hiring for peak demand would result in excess labor and unnecessary cost during slower periods, while relying on temporary labor introduced variability in both quality and execution.

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Vivid Impact needed a way to scale labor in line with production requirements without compromising performance or inflating overhead.

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Building an Operations That Can Scale With Demand

To address this challenge, Vivid Impact incorporated Veryable’s on-demand labor marketplace into its operating model, creating a flexible extension of its full-time workforce.

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This approach allows the company to adjust labor capacity on a daily basis, aligning headcount directly with production needs as they change throughout the month.

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As a result, the operation is no longer constrained by rigid labor. Instead, labor scales in step with demand, enabling the team to respond to both planned surges and real-time changes in workload.

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This flexibility has also played a critical role in ramping the Mesa, Arizona facility. By leveraging on-demand labor, Vivid Impact was able to bring the new site online quickly and establish a fully functional operation without the delays typically associated with hiring and onboarding a large workforce.

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Today, with established labor pools at both the Louisville and Mesa facilities, the company can scale production capacity across locations while maintaining consistency in execution.

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Executing Through Peak Demand Without Disruption

The impact of this model becomes most visible during peak production periods.

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In October, during the largest surge to date, Vivid Impact was able to scale its workforce to meet demand, manufacture and assemble promotional kits, and ship orders to more than 7,000 locations on time. By aligning labor capacity with production requirements, the company significantly reduced its reliance on expedited shipping, lowering costs while maintaining service levels.

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This level of execution is driven by the ability to adjust labor in real time. Machine operator helpers are brought in to support skilled full-time employees, allowing experienced team members to focus on high-value tasks while increasing overall throughput.

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At the same time, kitting operations can scale rapidly. During non-surge periods, headcount may be minimal. As demand increases, the operation expands to a second shift and grows to as many as 45 operators across both shifts.

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Rather than forcing production to work within the limits of a fixed workforce, the operation adjusts to meet the requirements of the work.

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Improving Productivity Without Increasing Labor Costs

Beyond supporting peak demand, this model has also improved how work is executed on the floor.

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By assigning non-value-add tasks to on-demand operators, Vivid Impact allows its full-time workforce to focus on core responsibilities that require higher skill and experience. This has led to increased productivity and output, while also improving morale among full-time employees.

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At the same time, the ability to scale labor down as demand decreases ensures that the company is not carrying unnecessary cost during slower periods. Labor is applied where and when it is needed, and removed when it is not.

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This balance between flexibility and control allows Vivid Impact to maintain high service levels without introducing inefficiencies into the operation.

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What Changed

By restructuring its labor model to align directly with demand, Vivid Impact built an operation that can absorb significant variability without sacrificing performance or increasing overhead.

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The result is a production model that remains stable through peak demand while avoiding the cost and inefficiency of overstaffing:

• Meets large-scale production requirements and ships to 7,000+ locations on time during peak periods
• Reduces reliance on expedited shipping by aligning labor capacity with production schedules
• Increases overall throughput by supporting skilled employees with flexible labor
• Scales kitting operations from minimal staffing to multi-shift production without disruption
• Avoids excess labor costs during slower periods by reducing headcount as demand declines

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Operational Snapshot

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Work Areas

-Kitting/Fulfillment

-Inventory Receiving

-Machine operator helpers

-Forklift operator

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Labor Pool Size

Louisville - 111

Mesa - 125

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Attendance

Louisville: 92%

Mesa: 93%

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Op Posting Lead Time

Louisville: 17.49 hours

Mesa: 23.23 hours

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