Sep 26, 2010 | Demand chains, Management, Operations, Strategy
A while ago I wrote that there seemed to be the beginnings of some thinking amongst the smaller manufacturing operations I interact with about the relative value of manufacturing in high cost Australia, and retaining control of, and having the opportunity to develop, the intellectual capital involved, rather than sending manufacturing offshore in pursuit of lower costs.
I came across this article reflecting the same view, but amongst some of the biggest manufacturers in the US, and it also reflects the beginnings of this trend.
In Australia, we have let our trade skills erode so dramatically over the last 25 years that if we do start to see some sophisticated manufacturing return to our shores, and the obvious contender is photo-voltaic cells, now almost exclusively manufactured in China with Australian technology, we may not have the technical manufacturing skills to deliver.
If this nascent trend does harden, it will usher in a huge gap in our operational skills capability, one that will take a generation or more to fix, and most importantly to any solution, we need a recognition by federal and state politicians that we have a problem bigger than the next election cycle. The long term investment in education and the culture changes necessary will add another big chunk of time to the reaction, possibly a generation.
Sep 15, 2010 | OE, Operations, Small business
Focusing attention holistically on a whole process, end to end, and the productivity of the process will improve, improving the outcome.
When you focus just on the outcome, all you get is the opportunity to improve the efficiency of the existing process, but it will have no sustainable impact on the productivity of the process itself, and inevitably when you just focus on efficiency of one part, over time the whole process will at the very best, remain at the stable level, because as you make efficiency improvements in one spot, in another, something has gone wrong to reduce the efficiency of that point in the process.
If you want to improve, focus on the whole process, not pieces of it.
Sep 14, 2010 | Change, Management, Operations
In any environment, those on the front lines see ways to complete a task easier, faster, cheaper, better, simply because they are doing it all the time, it is just that we usually do not listen enough when the front line employees they try to tell us, and once bitten twice shy.
Labor costs are typically seen as an expense, something to be trimmed and managed, rather than as an investment that can be optimised and leveraged.
All the fancy computer programs, training, and supervision in the world will not even begin to replace the value of an engaged employee who has some control over his environment, and recognition for making it more effective.
What is it like in your factory?
Sep 9, 2010 | Management, OE, Operations, Small business
It seems almost all improvement programs I see have as a central objective the reduction of inventories. That is pretty easy to achieve, order less, less often, and in smaller quantities, objective achieved.
However, when you count customer service, and cycle times into the equation, something the financial inventory measures do not do, reduction of inventory can have a catastrophic impact on financial results, as if nothing else changes, you just fail your customers.
Reduction of inventory is usually an outcome of the reduction of waste, but should not be the objective, waste reduction, waste in all its forms, should be the objective.
Sep 7, 2010 | Management, Operations
We all find ourselves dealing with ambiguity, preconceptions, vested interests, status quo methods, and often hubris as we set out to consider options in any management situation. In these circumstances, we usually mix quantitative data with what we know, and what we believe in a varying recipe that delivers a result we are comfortable with.
In this post by Eric Paley, the tensions inherent in these differing and mixed methods of analysis are beautifully articulated in a sporting story most can relate to.
Sep 2, 2010 | Change, Customers, Marketing, Operations, Sales
We spend lots of time dreaming up new stuff, but there are almost always things that we take as given, things that we do not question, usually because they are so basic, that we never think to do otherwise.
Many years ago, a part of my responsibilities was for the marketing of Ski yoghurt in Australia. At that time, all 1kg yoghurt came in round tubs, it was easy, cheap, all the filling equipment was designed for round tubs, as it was the cheapest shape to produce and print, anything else was a dumb idea, and would cost a motzza. I changed Ski to a rectangular tub, and sales tripled overnight, and the market was changed. Consumers for a number of simple, practical, but to then unspoken reasons, preferred a rectangular tub
The whole industry had been dependent on the manufacturers of the filling equipment, who supplied machinery designed to deliver the least cost option, nobody was silly enough to even consider an added cost alternative, so round tubs were the standard, all operational equipment was optimised for round tubs, and the suggestion that you should retool a factory for an alternative was never considered. It’s just that consumers when given the choice abandoned the round tub overnight, and retailers, reaslising a rectangulat tub offered better shelf utilisation, were happy to put them on shelf.
When looking for opportunities, consider the things that are just “there” that are part of the fabric, and are as a result taken for granted, and find one to change.
