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Delivering Bad News to the Customer

March 4th, 2010 by Roger

Whether your business is building wooden pallets or designing nuclear power plants (or anything in between), it’s safe to say that you’ve had to share bad news with some of your customers at one point or another. And who likes to do that?!? Human nature is generally to avoid these negative situations as long as possible, and consequently the problem only continues to get worse. In my experience, if you follow a few simple guidelines in delivering bad news, you can make life more manageable for yourself, your company, and particularly your customer. The news itself can be anything from a schedule slip to budget overrun to a technical catastrophe, but the rules for handling the news really do not change much.

Here are some of the guidelines that I have adopted over the years to help deliver ‘less than stellar’ news to my customers:

  1. Bad news never gets better with time!  If you only retain one single fact from this reading, make it this one! Don’t waste valuable minutes, hours, days or weeks hoping that the problem will all go away or get better on its own. The harsh reality is, these things seldom solve themselves. Be prepared to share the news with your customer as soon as you validate it. Remember that they too have made commitments based on YOUR performance, so keeping facts from them is going to make things even worse on their end when the truth eventually comes out. And it ALWAYS comes out, eventually. The sooner everyone knows the problem, the easier it is make arrangements to deal with it. I always try to put myself in my customer’s shoes when I need to be the bearer of unfortunate news. This helps to keep a balanced perspective, and in the end you will be able to serve your customer’s needs better. Another crucial point to remember: It’s not at all uncommon for the customer to be able to help craft out the solutions. It’s possible that they have run into similar issues on other efforts, so the sooner they are engaged, the better. Don’t forget about this valuable resource for resolution plans, especially if you’re stumped about what to do next.

  2. Ok, so now you’re prepared to break the news……Make sure you have all your facts straight first! Understanding the root cause of the issue is the first step to dealing with it, so make sure you can identify it clearly in your discussion. Spend ample time getting all of the info relative to the issue at hand gathered and sorted before your discussion. Before you make that dreaded customer call, bring together as many of your team members that are involved in the project as you can and have a brief rundown of the what/how/why questions with the group, and take detailed notes of this meeting. In my personal experiences, these meetings have saved me from many embarrassing “well, I don’t really know……” statements during the delivery of the bad news. Try to anticipate as many of their questions as you can, and make sure you have as many of those answers as possible available to you before you have the unpleasant discussion with the customer.

  3. Don’t EVER pass off the dreaded task of delivering the negative news to someone else. Many times middle-management personnel will bring in the ‘big gun’ VP or Director to break the news to the customer. This happens for a variety of reasons (don’t want to be the ‘bad guy’, execs may feel more comfortable spinning the bad news than allowing a subordinate to do it, etc.), but seldom are the reasons valid. When I’m the customer and my everyday contact brings in someone I hardly know (or don’t know at all) to break bad news to me, I have a hard time trusting and respecting either one of them. If you need some backup in the room, that’s another story. It never hurts (and in fact is usually a good idea) to have moral support or ‘color commentary’ from another member of your team during the discussion, but you need to be the bearer of the bad news. Period. Your hard-fought reputation and relationship with your customer may hang in the balance on this one if you choose the seemingly easier path of “let someone else deliver the bad news”.

  4. If at all possible, try to have at least some general ideas close at hand of how to you may be able to mitigate the problem. Even better if you already have a firm plan of action figured out and in process when you break the news to the customer. However, don’t spend days or weeks working on your plan before you break the news. You have to be quick on this one (see rule #1).

  5. If your team is directly to blame for the bad news, own up to it candidly. Nothing makes a customer lose faith in you quicker than trying to shift blame to some other entity. Own up to the culpability, take whatever whipping that’s dished out, and then move on to the solution phase. It’s hard for anyone to put much energy into mercilessly flogging you if you’ve already done it yourself in their presence.

  6. Move your customer communications to “crisis-mode” during the recovery phase of the problem. Provide daily (sometimes multiple daily) updates to your customer contact with the progress and the direction that corrections are taking. This will make the customer a true partner in the effort, and it also makes it a lot easier for them to be able to deliver updates to their stakeholders. Remember: Once the bad news is out in the wild, everyone along the chain will be constantly tuned into hearing the solution progress. If your customer is getting hammered every hour by his boss about what’s going on and he doesn’t have the answers, the pressure ramps up unnecessarily for all involved, particularly you!

  7. If your correction plan takes a drastic turn from your published course for any reason (plan A didn’t work, the team came up with a better plan, etc.), be sure and let your customer contact know immediately (see rule #1). This bullet point probably should really be 6B, as it ties in directly with standard crisis-mode communication.

I’m sure there are dozens of other rules and guidelines that could apply to this list, but these are the mainstays that I use to try and keep problematic project issues from becoming business-killers. If you are able to utilize some or all of these methods the next time you’re faced with explaining a catastrophic setback to your customer, I think you’ll find the situation can not only be more manageable, but your customer ties will only get stronger. True partnership demands the whole truth be shared in a timely manner, and anything less will only complicate your problem. And one last point to remember: In our modern world they seldom execute the bearer of bad tidings anymore like the old Roman custom, so you have that going for you, which is nice! 

If you have some additional rules or guidelines of your own that you’ve refined over the years for delivering bad news to your customers, please share them here! We can all use all the help we can get when we have to be that bearer of the dreaded news.

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Our Annual 5 S Lean Cleanup

February 18th, 2010 by ksmith

Each year at Setpoint as we begin the New Year we go through the 5 S process in our office.  We sort through everything at our desks, the shop, closets, and in the office in general to clear out those things that we no longer need or use.  Then we straighten everything up and rearrange stuff to clean things out and make it easier to find items that we use. 

This year as I was preparing to lead the 5 S cleanup the decision was made to cleanup our Intranet instead.  We got rid of so much over the last few years and hadn’t really accumulated much since our last cleanup.  However, our Intranet is about 5 or 6 years old and instead of cleaning old files off as they were no longer needed and keeping the architecture up to date as we went along, new links and pages were added instead.

If you ask the CEO to find a document on the Intranet he won’t be able to.  He tells me all the time that it’s confusing and that it takes too many clicks to find anything.  How in the world do you start sorting through the Intranet?  I started by making a list of every page and document that we had on there.  We have over 500 items on our Intranet, I had no idea.  Some of those items were duplicates where the same document was added into two different sections.  At least I knew what I needed to sort through.  It just goes to show that when you don’t pay attention to something, it can get totally out of hand as everyone keeps adding things that are not necessary.

The next thing I did was to ask everyone what documents they actually use from our Intranet.  For the most part, there were four documents that most people use.  The rest are either once in a while or they are not used at all.  That was an eye opener, why do we have so many documents available if no one ever even looks at them. 

Now it is time to straighten everything up.  Those items that are used will need to be grouped with like items so that within three clicks you can find any document on our Intranet.  I also need to come up with better category names so that by looking at it you will know what is included, rather than generic terms like “Forms”.

So I’m off to get these items straightened up.  Hopefully the next stage in this process will be easy.

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Value Curves

February 11th, 2010 by Brad

As a pretty consistent reader of Harvard Business Review magazine, I find that there are many articles that are good and occasionally there articles that are very stimulating and worth remembering. Those articles make me think and give me new ideas to consider as we steer our business to be more successful. One of those articles that I read many years ago was, “Value Innovation – The Strategic Logic of High Growth”. It comes from the July/August 2004 issue. It is authored by W.Chan Kim and Renee Mauborgne. I pulled it up again and read it as we are trying to chart some new courses in our business. In addition to that article, they also have written a best selling book named Blue Ocean Strategy, you may have heard of it, it is also worth the read.

In the article they point out that most industries compete around the same points of competition and it becomes a race where everyone makes incremental changes in how they compete, but not very often does anyone truly have a breakthrough in how they approach the marketplace. The basis of the article is that incremental points of competition pushes the products or services towards commodity pricing and fights over small changes in market share, no big gains are possible with this strategy.

If you want to make major changes in your industry you have to think differently. Below is an example of their value curve research.

Value Curve

Value Curve

Every industry completes on certain factors. I’ve labeled this example with 6 factors that are along the X axis., there may be more or less in your industry. If there are too many, I’d suggest you boil them down to the few that really matter. It will be hard to figure out what to do if you have too many. Factors vary by industry, some may be the same and some will be unique to your industry. Examples of factors may be cost, features, size, quality, etc. Spend enough time to make sure you really have what the points of competition are, not what you wish they were.

Along the Y Axis we have a relative scale – from high to low, expensive to cheap, many features to few features, etc. depending on what the factor is, you get the idea.

In this example the existing competition is the blue solid line. Based on the factors you can see that the factors fall in different places to the relative scale. In a typical industry the competition will nudge these factors incrementally up and down the relative scale trying to gain market share, but not changing the Value Curve in any significant way.

In this example, a newcomer arrives with a completely new strategy. This is represented with the pink dashed line. You can see that this strategy completely redefines the blue value curve in which the current players compete. Pink is significantly changing how they are going to compete by significantly changing the relative value of factors 1, 5, and 6. If they are successful they should enjoy success and their research says they will enjoy many years of uncontested competition.

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Implementing Lean Manufacturing

January 21st, 2010 by Clark

How far can you take lean manufacturing practices before you cross the line of what makes sense economically versus doing what a pure lean implementation tells you that you should be doing?

We have all heard the statement, “You were too close to the forest to see the trees.”  I think at times, in our eagerness to adopt lean manufacturing principles and practices we find ourselves “Too close to lean that we sometimes can’t see what makes sense.”

To illustrate this situation let me tell you about a company that was faced with a similar situation.

The company was a major player in the medical products/device manufacturing industry.  They had adopted a lean philosophy plant wide and had been following lean practices for about 5 years.  They had seen fantastic results as they broke down traditional methods and practices and followed the lean manufacturing principles to a “tee”.

They had done a superb job of connecting their processes in their various value streams and had managers of each area that believed in lean but were having a difficult time understanding how to decide what was right for their next efforts along the path of continuous improvement and lean implementation.

They were trying to achieve a single part flow into a low volume, high variety type of job shop assembly area.  They had established supermarkets for each the components that were required by each value stream.  In their hopes to fully connect the component manufacturing with the component demand in the value stream cells they were contemplating bringing some fabrication equipment into several of the value stream cells to reduce supermarket inventories of certain critical parts and to perhaps better connect the process.

The fabricated parts required multiple machine center resources to complete.  Many issues related to safety, cleanliness and process flow also needed to be considered.  The existing fabrication center was set up in a “U” shaped cell and actually ran very well.   Additionally, the existing fabrication cell supplied component and services to several other value streams within the plant.  After much contemplation and study, the group agreed that bringing the fabrication cell into the assembly areas would be a big mistake.

What came out of this study is that you can actually find better ways of fully connecting the processes in the overall manufacturing operations without actually having to physically locate all associated production tasks in the same cell.  With a little work and thought, the supermarket inventory levels were dropped, the communication of TAKT time demands were better established across the lines of fabrication and assembly, and the customer began to realize immediate benefits of better connecting their processes.

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Why does the huddle work at Setpoint Systems?

January 14th, 2010 by JoeK

Setpoint Systems is an open book company. This means that our books are open to our employees. Even though we are a privately held company we choose to share our financial information.

When the company started in 1992, the engineer founders Joe Cornwell and Joe VanDenBerghe (aka the Joe’s) decided they wanted to share financials with their employees. As a project based company they found that the way their part-time CPA did the books with them did not give them a good measure of how the projects were performing financially on a week-to-week basis.

So the two Joes with the help of others developed a way of tracking their projects on a weekly basis that included hour tracking by labor section, material costs tracking, and earned value project management concepts. This allowed a fairly accurate measure of the financial performance for projects on a weekly basis. This type of the project financial analysis did not comply with GAAP (The Generally Accepted Accounting Principles). Their CPA did not like it but it made sense to them and their employees.

The weekly tracking process happens on a big white board where projects are measured for material costs and percentage progress every week. The key project number, that every employee follows, is GP or gross profit by project (at Setpoint GP is simply earned revenue by percent complete less actual material costs). After the gross profit by project is measured then we compare that to our week OE or operating expenses. You take GP – OE to measure our profit for the week.

We track closely three measures on our huddle board. First, is GP/OE. For us, 1.2 is good and anything less is not good enough to sustain the business. Second, we track what percentage of our labor is direct to our automation projects. Third, is GP per direct hour charged to projects. Everyone knows that if our GP per hour is over a key threshold and our percent direct is over a key threshold Setpoint will make a nice profit and GP/OE will be well over 1.2.

It’s actually a really simple system. We have a monthly and annual bonus that pays out based on beating minimum GP-OE targets for the month and year. We also train all of our employees on how the huddle board works and what the key metrics mean.

So why does our huddle work? Well I think that there are few things that have made this simple 15-minute weekly meeting work for Setpoint. First, it’s a simple way to track projects and everyone understands it. Second, we tie objective financial rewards to how the board looks. Third, we involve every employee in the process. In the weekly huddle every employee has a seat at the table.

The power of Setpoint’s weekly huddle is evident in the survival and success of this business. When a project is bad on the board, the assembly people blame the design and engineering people, the design and engineering people say the project was under funded when it was sold and blame sales. We are all together in the meeting and it needs to be worked out between these groups or we do not have a business. The huddle creates at Setpoint what I like to call ‘psychic ownership’. Ever though all the employs do not own stock in Setpoint they act like owners because they see the performance on a weekly basis and want the company to perform well.

We have seen this ‘psychic ownership’ express itself in many ways over the years. Recently, when a project was nearing completion some shop people approached our CEO and challenged the percent complete shown on a specific project. They were in final assembly and thought the machine was well beyond 90% complete but our project engineer had the number much lower on the huddle board thus lowering our GP-OE and bonus for the month. In short, our assembly people accused the project engineer of sandbagging on the project. After a brief review an adjustment was made. We’ve also had situations where percent complete has been challenged as being farther along than we really are.

With everyone involved the huddle really keeps us safe and accurate on our business. We believe the huddle process and the systems behind it is the single greatest asset that Setpoint Systems has.

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Being the “mother” at Setpoint

January 5th, 2010 by Setpoint

I’m not sure I like the title of Mother at Setpoint. I guess because then I am the oldest female working here. Aside from that it has its advantages. Sitting at the front desk and being in charge of the candy dish people come to my desk often. So while they are there they will tell me about their family and what they did over the weekend or what their plans are for a vacation. I know most of their family and now I can ask how they are doing. Most people like to talk about their family and so it’s been fun to get to know them in a more personal way. Being the mother of 4 children it’s a natural thing for me to get involved in all the employees personal lives.

I think being older and having raised a family sometimes people will come to you with questions and ask for advice or some input on a situation. Just watching them with their kids makes me smile to see what good parents we have at Setpoint. They are all striving to become great parents.

Being the mother also means that you see the kitchen and think that someone will clean that mess up but after a couple of days and it is still there you just clean it up because it’s easier than finding out who made the mess and will I ever find out who did it? Probably not. Whenever we have a Setpoint party it seems that the girls always seem to get the clean up job so I do have some help there.

My job at Setpoint is to hand out the checks so it’s kind of like allowance that a mother will give her kids. So everyone likes to see me coming when I have checks that’s always a plus.

I like my job at Setpoint and it is my family away from home since we spend a lot of time at work. There is a special bond and we are all concerned about everyone else. Last year my husband lost his job and everyone was so concerned about me I knew that if I needed anything they would be there for me.

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Project Cash Flow Forecasting

December 16th, 2009 by Machel

Bidding on large projects is bittersweet.  If you have an opportunity to bid on a project that could be either a blessing or a burden, it is important to manage the cash flow.  Because cash is King, it has the ability to put you in a castle or a shack.  What kind of living quarters you live in can be decided by cash flow.  A significant number of companies go out of business because of lack of cash, not a lack of great ideas.

When bidding on large projects there are a few questions that need to be addressed.  First, when are the costs of the project due?  Second, when will the majority of the labor be needed?  Third, what size of a down payment do I need?  When do I need progress payments?  Most companies think the down payment question should be answered first, but that is not always the case.  It is necessary to know when your costs are going out so you know what size your down payment needs to be and when your progress payments need to come in.

Let’s assume some facts for our example:

  1. Revenue on the project is $3,000,000
  2. Cost of Goods Sold (COGS) are $1,500,000
  3. Operating Expenses are $10,000 for the first 4 months, then gradually less as the project closes

Project Cash Flow at a 30% Down Payment

 

Jan-10

Feb-10

Mar-10

Apr-10

May-10

Jun-10

Jul-10

Income

 

 

 

 

 

 

 

Invoiced

900,000

 

 

1,500,000

 

600,000

 

$ Rcvd

 

900,000

-

-

1,500,000

-

600,000

COGS

 

 

 

 

 

 

 

Estimated COG

 

450,000

450,000

450,000

150,000

 

 

Total COGS

-

450,000

450,000

450,000

150,000

-

-

Est OE

 

10,000

10,000

10,000

10,000

5,000

3,000

Total Cost

-

460,000

460,000

460,000

160,000

5,000

3,000

Net Effect

-

440,000

(460,000)

(460,000)

1,340,000

(5,000)

597,000

Cum Effect

-

440,000

(20,000)

(480,000)

860,000

855,000

1,452,000

Project Cash Flow at a 50% Down Payment

 

40,179

40,210

40,238

40,269

40,299

40,330

40,360

Income

 

 

 

 

 

 

 

Invoiced

1,500,000

 

 

900,000

 

600,000

 

$ Rcvd

 

1,500,000

-

-

900,000

-

600,000

COGS

 

 

 

 

 

 

 

Estimated COG

 

450,000

450,000

450,000

150,000

 

 

Total COGS

-

450,000

450,000

450,000

150,000

-

-

Est OE

 

10,000

10,000

10,000

10,000

5,000

3,000

Total Cost

-

460,000

460,000

460,000

160,000

5,000

3,000

Net Effect

-

1,040,000

(460,000)

(460,000)

740,000

(5,000)

597,000

Cum Effect

-

1,040,000

580,000

120,000

860,000

855,000

1,452,000

Following the tables listed above, if you change the down payment from a 30% down payment to a 50% down payment, you go from needing $480,000 to not needing any additional cash at all during the entire project.  This is assuming a progress payment is scheduled four months into the project.

A spreadsheet like this does not take very much time to set up.  By putting in that extra time your company can go from living high on the hog to searching the couch cushions for change.

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5 S Process in an Assembly Shop

December 10th, 2009 by ksmith

Recently we talked about the 5 S process developed from the Toyota Production System.  Some believe that the 5 S process can only be implemented in a manufacturing environment and do not see the benefits of using this process to improve their work environment.  Here at Setpoint we have our design engineers in an office environment and our assembly technicians in a shop environment with both areas using the 5 S process. 

We made a video and put it out on YouTube to walk through our shop and show how the 5 S Process can be implemented in an assembly environment where we build one machine and ship it, then build a completely different machine.

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Return on Investment (ROI) Calculator

December 3rd, 2009 by JoeK

The ROI (Return on Investment) calculator is a new tool added to Setpoint System’s web site.  This tool allows you to measure the viability of a potential automation project that Setpoint Systems could provide.  The tool requires the following information. 

First, you need to provide and estimate of the total cost of the automation project.  This cost is more than just the cost of the equipment.  It should include items like installation and support. 

Second, the ROI tool requires your best estimate of the annual savings the automation will provide.  These savings could include added profit from increased volumes, labor cost savings, lower scrap rates, floor space savings, and higher consistency in the output. 

Third, you will provide the number of years the annual savings will be realized. 

Fourth, you will provide the minimum annual interest rate return required for the automation equipment.  This rate is often provided by your finance organization.  It is a measure of the return that the money invested in your business should get.  Some call this the hurdle rate or the cost of invested capital in your business if you want to use finance jargon.

Once you have entered these inputs into the ROI Tool, you will get an output report.  This report will provide three ROI metrics that your finance guru will love.  They are NPV (Net Present Value), Payback, and IRR (Internal Rate of Return). 

NPV measures the amount of money the project returns in today’s dollars when compared to the initial investment.  A NPV below 0 means you are better off rejecting the investment because the benefits of the automation in today’s dollars do not cover the initial costs.  On the other hand, a positive NPV tells you that this investment beats your initial required rate of return in using current dollars. 

Payback simply tells you how long it will take to get your initial investment back - clearly the shorter the payback the better.  Payback is a simple tool that is used for a reality check.  Since it does not consider the investment to the return in current dollars, it is considered inferior to NPV and IRR. 

IRR measures the rate of return that the project pays out based on the initial investment and the return information.  If the IRR is higher than the minimum annual interest rate, then you are getting a better return than the minimum.  IRR method is a terrific way to present a project to management.  If your IRR is 25% on a project and your minimum required rate is 12%, you can say that this investment beats your required rate by 13%.  You would be crazy not to proceed with this project.

So have fun with this exciting tool.  I know a lot of you working on automation are technical.  I hope that you realize that this tool can be as exciting as running calculations on your old HP 11C calculator.  It can also help your company make more money.

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Whose Decision is it Anyway?

November 18th, 2009 by Brad

It is way too easy to say that because I’m the boss, I decide. That is a very autocratic approach, and your company will only be as good as the dictator at the top making those decisions, and there has never been a dictator that gets it right all the time.

The opposite view might be that you require consensus with all those involved before a decision can be made. In my experience, very rarely will everyone agree unless the decision has no consequences or you have a team of suck-ups. Have you ever heard the saying, “if two people in a company always come to the same conclusion, one of them is not necessary”. Not making a decision because everyone is not at consensus can be paralyzing to a company. Being unable to decide is a decision also, which can have disastrous consequences

Setpoint is unique in that our culture promotes ideas and debate regardless of who is on the other side of that debate. Pretty much everyone at Setpoint feels comfortable enough to tell me when they think I’m up in the night, and that happens all the way up and down the organization.

I have worked in other places where there were taboo subjects that you could not talk about in front of certain executives or owners. That has an unbelievable stifling effect on ideas and choices that come forward and can be considered. The worst part is that those executives never engage their organizations brains and get the benefit from those that are working closest to the challenges.

Creating the right environment for deciding:

  • You must create an environment where ideas can flow freely, with no repercussions
  • Make sure it fits into the strategic direction of the company
  • If you are surrounded by smart people and they are telling you not to go the direction you are thinking, maybe you should stop and listen to them because you might not have the best idea
  • At the end of the day what you and everyone in your organization should want is the decision that best fits for the direction you are heading
  • Very rarely will you have perfect information and data to make your decision, nor will the same checklist work for all circumstances
  • In my career it has been more important to recognize when you are off-course rather than holding off deciding until you have all the data you need to make a decision
  • If you do not give credit to those contributing the idea, it’s not hard to know who will decide in the future, it will be you because no one else will put their ideas forward
  • Have milestones where you check the validity of the decision to see if it is on- track or if modifications need to be made

Good luck in creating an environment where good decisions can be made.

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