Tag: manufacturing
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Top 3 Survival Tips for Manufacturing
1. Have visibility into what is selling
2. Streamline your product offering based on sales
3. Customize your supply chain to your product offering and demand signal (Read as “educate the supply chain of the product based on sales”)
A manufacturing operation that is disconnected from sales is bound to have high inventory and poor capital utilization – both being extremely detrimental to profitability. continue reading »
Q&A with John Sloan, former director, Jeep Brand Global Product Marketing
In today’s post, John Sloan talks about challenges dealers face in ordering inventory that best matches customer demand.
Emcien: Describe the Chrysler-Emcien initiative that examined dealers’ struggles with complexity in the ordering process.
JS: In a soft “push” market where volume is driven by heavy incentives versus the merits of the brand / model, managing cost is paramount. A key piece to focus on is product inventory. Dealers get roughly 60 days of no-interest floor plan. In a soft market, vehicles can easily sit for longer than two months before being sold, so it’s critical that vehicles be easy to order, stock and sell. Simple is better.
Emcien worked on a model to simplify the Chrysler PT Cruiser product mix. There were thousands of possible build configurations for the PT Cruiser, creating significant complexity for engineering and the assembly plant, as well as the supplier extended enterprise. Emcien’s ability to accurately forecast demand is invaluable for a complicated product line because it can assist with reducing the build configurations to those that best match demand. The PT Cruiser initiative validated the power of the Emcien inventory model.
The quality connection
Recently I wrote about quality rankings for automotive manufacturers and the perception of these rankings in the market. While the marketing teams at these companies must shoulder the burden to convince consumers about their products’ quality, there is a very real connection between product quality and configuration management.
In many industries where products have grown over time with constant additions of new features and flexibility to allow customers to build to order, the level of complexity is staggering. Often the number of configurations sold on an annual basis is surprisingly close to the total units sold for that same period. This “snowflake” situation is one of the worst possible scenarios in product complexity as each unit has its own signature. Obviously, the production of these products also requires flexibility in manufacturing. This may result in reduced use of automation, and often it leads to units being reconfigured where components installed during one step are either removed or modified in a later step due to a unique situation.
These one-off manufacturing processes open the door for product quality issues due to fewer controls during production. Put simply, if I can reduce the number of different things that must be done during production I should be able to do those things better.
So product management teams have direct input on product quality via product complexity. Managing the product option mix to reduce the overall number of configurations can promote the increased quality that all manufacturers are looking for.
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How many choice combinations does your product have? That depends.
Possible combinations
This is a question with several answers. The easiest answer is the least useful. The number of possible build combinations, or unique configurations, is easily computed by multiplying the number of options for each feature. For example, if your product has feature A with 3 options, feature B with 2 options and feature C with 4 options, then there are 24 (3 x 2 x 4) possible build combinations.
These numbers grow very rapidly. If you have 5 features, each with 4 options, there are about 1,000 build combinations (exactly 1,024). With 10 such features, the number of combinations is about 1 million (1,048,576), and with 15 features it is over 1 billion (1,073,741,824).
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Stop product complexity at the door
In any manufacturing company that builds configurable products, there is a lot of discussion around what product complexity is. What’s interesting is that when times are good and there are lots of sales, the discussion is usually around how to simplify or streamline with the goal to sell more product even faster, that complexity is keeping sales from going even higher. In bad times, the discussion typically moves to how complexity is causing undue stress on the supply chain, creating problems with parts forecasting, quality and finished goods inventory.
Rarely do these discussions end with participants really agreeing about exactly what complexity is or how to reduce it. Solutions are attempted with internal projects like SKU reduction and part number reduction initiatives driven by Six Sigma teams that mean well and do good work, but usually are chasing the tail of the complexity dog, rather than leashing it for good and guiding it to higher profits, lower forecasting errors, even shorter sales cycles.
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Is quality really important?
Seems like it’s almost fashionable to kick the three U.S. automakers these days, and I rarely hear people mention U.S. built as one of their first choices. Yet people almost always cite reliability as one of their most important criteria for buying a vehicle.
The most recent J.D. Power and Associates rankings show that 2 of the top 5 highest-ranked brands for vehicle dependability are from U.S. automakers. Two other U.S. brands had top rankings in other vehicle segments. It seems that many foreign makers have a perception of quality that is based on past success or marketing. Manufacturing of products in the U.S. has seen a steady rise in quality over the past 10-15 years; the perception in the marketplace should keep pace. If nothing else, the data points out that buyers should consider U.S. brands and not jump to conclusions on outdated results.
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