Gallagher Guitar Company Tunes Up for the Future with the Tennessee Manufacturing Extension Partnership

MURFREESBORO, TN – Gallagher Guitar Company, a name synonymous with handcrafted acoustic excellence since 1965, is making more music than ever before, thanks to assistance from the Tennessee Manufacturing Extension Partnership (TMEP). The collaboration has helped the Murfreesboro-based company, known for instruments favored by the likes of music legend Doc Watson, streamline its production and increase efficiency while maintaining its legendary quality.

Owner David Mathis, who grew up in middle Tennessee and learned his first chords on a Gallagher, brought in TMEP's expertise to help his team embrace Lean Manufacturing principles. The goal was to increase efficiency and profitability, ensuring the company's legacy endures for generations to come. Mathis is committed to building guitars that are “consistently of the highest quality” and true to the Gallagher family legacy.

TMEP’s Chad Arcand led a five-week program that integrated classroom instruction with real-world application. This approach enabled participants to immediately apply new skills on the shop floor, with a focus on identifying and eliminating waste and other non-value-added activities in the production flow. The outcomes have been transformative, driving meaningful improvements in efficiency and performance.

According to Mathis, the partnership has encouraged a new way of thinking among the employees. “It’s amazing the little things they think about,” he says, noting how the team now considers efficiency throughout the entire process. This shift has led to significant improvements, including a reduction in labor hours per guitar and an increase in the number of instruments produced each month.

Lead Luthier Austin Derryberry, an accomplished musician and skilled craftsman, attests to the program's success. “Everybody’s on-board,” he says. “We are doing more than ever, and the quality is better than ever. This is a much different shop than when you (TMEP) were first here.”

The improvements are tangible. The company has focused on what customers truly value, leading to a reduction in lead time for guitar production. A key example is a new finishing process that requires significantly less labor. They also developed a new vendor to supply some of their milling needs which facilitates better use of their time and machinery. The lessons on flow and efficiency translated directly into the layout of their new shop at 331 N. Front Street in Murfreesboro, TN, which they moved into this past September.

The newfound efficiency means the company can produce more guitars with fewer people, all while maintaining the superior craftsmanship that Gallagher customers have come to expect. This allows Gallagher to meet growing demand and continue its tradition of building high-quality, custom instruments.