Manufacturing Executive

Innovation: Does It Take a Crisis?

A different perspective on what drives innovation was voiced at Managing Automation’s Progressive Manufacturing Summit this week in Sarasota, FL.

Jose Bravo, chief scientist at Shell Global Solutions, believes that one of the best motivators for innovation is when a company gets into dire straits.

“A crisis is an enabler of innovation,” Bravo said, during a one-on-one conversation on stage with MA senior editor Stephanie Neil.

Is he right? Does a company have to be in trouble to innovate? Does a crisis situation create better conditions for innovation?

Surely, companies don’t need to be in crisis mode to innovate, but having a compelling sense of urgency can certainly help. Nothing motivates more than a knife at the throat, as the old saying goes. Still, Bravo’s point is well taken. Companies, like individuals, shift into survival mode when they feel threatened, enabling them to do things they wouldn’t do under normal circumstances.

Better management, though, can move organizations to innovate continuously — without the threat of a crisis. After all, if your company has to wait for a crisis to figure out what to do or build next, it is apt to get into a vicious cycle of dependence on a crisis mentality. And that’s no way to move things forward.

David R. Brousell, Editor-in-Chief

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Sparks Fly at Steel Conference

Last week, a reported 1,500 people from the steel industry gathered in the Sheraton Hotel in midtown Manhattan to discuss steel industry trends. The conference, called Steel Success Strategies, dealt with such topics as: International Steel – Risks Now Exceeding the Rewards?; USA Steel – On-Going Rebirth?; and China, India, and the Middle East – Steel’s New Epicenter.

Hot topics, no doubt, and serious ones, too. The agenda for the meeting really reflected today’s realities, especially for U.S. steel makers. The topics must have produced much controversy during the day, but the sparks really flew – literally – on Tuesday night at a reception held by Deloitte, one of the consulting firms that serves the steel industry.

Deloitte must have made the assumption, correctly, in my judgment, that such a serious discussion agenda during the day required a bit of levity at night. So Deloitte brought in as entertainment a most unusual act – Grindergirl, also know as Kiva Kahl, whose performance will really get your attention.

Dressed in a metal costume that resembles Brigitte Helm as Maria the robot in the 1927 classic silent film Metropolis, and armed with what could be any Sears Craftsman electric grinder, Grindergirl’s act consists of applying the grinder to a steel plate attached to her mid-section. When she does so, sparks fly in all directions – to the amazement and delight of her audience.

I’ve never seen anything quite like it. Grindergirl has apparently been doing her act for years and has appeared on the David Letterman show, among others. You can check it all out at www.grindergirl.com.

–David R. Brousell, MA Editor-in-Chief

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Manufacturing Their Way Out of the Recession

Some large enterprises have apparently decided that now is the time to take decisive action in anticipation of economic recovery. Late last week, the Wall Street Journal reported that United Airlines has asked its aircraft suppliers Boeing and Airbus to bid on a deal to provide it with up to 150 new airliners over the next few years. The move comes despite the ongoing recession — at least among developed economies. But United is reportedly anticipating a recovery. So, rather than waiting until a turnaround is in full flower, the company is seeking bids now with the expectation that lower commodity prices now and manufacturers’ hunger for orders will mean good deals.

And United isn’t the only one playing this game. Chip maker Intel a while ago announced plans for a $7 billion expansion of three plants in the United States. And Exxon Mobil has said it will increase oil exploration and production spending by 11% this year, no doubt with the expectation that an economic recovery will stimulate demand and, once again, drive up prices (something that already seems to be happening).

Such moves are certainly not without risk. True, the tide of bad economic news is slowing. But 345,000 more unemployed in the U.S. in May and a 9.4 jobless rate, plus many billions of toxic liabilities (these are not assets) remaining on banks’ books make it hard to predict when a turnaround will occur and just how rapid or robust the recovery will be.

Still, now would be a good time for manufacturers to begin to change the capital-preservation-at-all-costs, bunker mentality that has dominated over the past 18 months and position themselves for recovery. Here are a few steps to consider:

  • Do some bargain hunting of your own. Deals are out there. Many suppliers are still desperate to land orders and forestall customer-base erosion. Consider starting with your software vendors. Many are publically taking the position that they are not willing to negotiate on maintenance or license charges. Behind the scenes, though, it may be a different story.
  • Rethink global supply chain risks and opportunities. The recession — and slower growth in places such as China — have exposed the risks inherent in blindly outsourcing production to the lowest-cost provider on the planet. Now would be a good time to seriously evaluate the strengths and weaknesses of all of your suppliers and manufacturing services providers. And, while you’re at it, develop risk mitigation strategies for selecting new suppliers in the future.
  • Position yourself to continue to benefit from the efficiency gains you’ve put in place over the past 18 months. Many manufacturers, out of necessity, have done a good job of reducing inventories and leaning out processes as demand has dried up. The best way to hang onto those efficiency gains is to improve your visibility into real customer demand so you can avoid ballooning finished-goods inventories and safety stocks once the economy and orders improve.
  • Create a real workforce development plan. Many manufacturers have been forced to reduce employee headcount in order to preserve capital. In too many cases they’ve lost important experience and intellectual capital in the process. While you probably won’t be going on a hiring binge any time soon, it’s time to put together a plan for how you will replace those lost skills and retain them during the next recession.

— Jeff Moad, MA Executive Editor

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A Supply Chain to the Moon

March 13, 2021. The debate over best practices for locating manufacturing operations ramped up again today, as NASA engineers announced more details on a federally directed initiative to colonize the moon.

The announcement was spurred by an executive order signed last month by President Jenna Bush, stating that America will create a bustling city on the moon by the end of the year 2022. At a White House press conference to announce the plan, Bush said it would “complement the work of my father, who we all know loves a good moon.”

The rush to pitch the first cosmic tents on the moon has created a bustling market for all manner of specially fabricated materials. The news has also revived a decades-old discussion about supply chain best practices; namely, where manufacturers should locate production operations — near the customer to shorten the delivery chain, or where workforce and regulatory conditions provide the best environment for their plants.

In the latest chapter of that debate, a bevy of startup companies is racing to break ground on the rocky surface of the Earth’s only inhabitable satellite. And some have sunk a proverbial stake in the ground.

“A responsible company manufactures its products on the celestial body where they will be put to use,” said Elaine Prost, president of Lunar Lids, a maker of hermetically sealed containers. (“So your cookies don’t get moon dust on them,” Prost explained in an interview.)

Officials at Galactic Beds, Inc., agree, and will face the same supply chain challenges as Lunar Lids. But CEO Daryl Best shrugged off any talk of obstacles.

Distribution of the company’s Man on the Moon products will be a cinch, Best said, noting that the distribution chain will be compact. Asked how delivery fleets would navigate the patchwork of rocky craters, he appeared unfazed. “I’m not wahrried about that. I’ve seen bigga pahtholes in South Bahstin.”

“Actually, I am a little worried about the labor pool,” conceded Prost. “We’re offering incentive programs to bring engineers and automation specialists to the moon. But I’ve heard talk about limiting ‘non-native’ workers. So I don’t know,” she said with a sigh. 

Other manufacturers, meanwhile, are determined to remain earthbound, intent on using cheap labor in locales such as Borneo, Antarctica, and Cleveland to produce materials such as gravity boots, lead-plated stock cars, and Tang for the pioneering moonies, as lunar citizens will be known. Details on how companies will navigate such a daunting supply chain remain sketchy.

“This gives a whole new meaning to the term ‘intermodal,’” chuckled Ted Franz, VP of operations at lighting manufacturer MoonGlow. With competition for first-mover status approaching fever pitch, Franz said he preferred to keep his company’s plans under wraps. He did, however, drop a tantalizing hint, saying, “You think ocean transport was cheap in the days of $20 barrels of oil, just wait until you see what we’re doing with rocket fuel these days.”

As was the case more than a decade ago, it appears there won’t be any easy answers to this debate.

—Chris Chiappinelli, Editor, ManagingAutomation.com

 

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Social Work

Like lemmings jumping off a cliff, we’ve joined the social networking circles: Twitter, Facebook, Flickr, LinkedIn, XING, YouTube, MySpace, Blogger… and many more collaborative outlets that we haven’t heard of, yet.

But, if you’re like me, you are stumbling and fumbling down a technology trail that doesn’t always make sense. I have to wake up extra early and stay up very late to find enough time to investigate these tools without cutting into my work day. At what point does this social networking stuff become destructive rather than productive?

It’s important to think about, especially when it comes to incorporating these applications into the corporate environment. There needs to be a business plan. I’m not talking about a human resources handbook that outlines appropriate Facebook behavior. Rather, line of business managers should be developing process workflows that include the use of these tools.

For example, where along a product development cycle would it make sense to have a link to a wiki for swapping ideas about a project? How about instant messaging? Shouldn’t that be a must-have (not a nice-to-have) when it comes to coordinating multiple constituents in real time?

It requires thinking about business with a different mindset. Of course, we all want to accommodate the up-and-coming generation of multitaskers who can hold 17 instant messaging conversations while texting two people, watching a YouTube video, and updating MySpace photos. That, however, is not necessarily productive. Efficient, but not productive.

Be selective and smart about how these tools are used. Zero-in on a subset of the vast array of options that make the most sense for the engineering department, for example, and then educate and implement, just like you would with any other technology project.

Take PTC. The PLM provider is in the early stages of introducing the concept of social product development, a term the company coined. They are using social networking tools very strategically. They are, of course, blogging — who isn’t? Within the next week or two, they’ll also be unveiling some very cool social computing capabilities that take product development to a new level.

Now it’s time to do some social ‘work’ of your own. Stop with the Google-drift (aimlessly wandering around the Internet by clicking on links), and start thinking strategically about how to use specific Web 2.0 tools to advance your team, your department, and your company.

– Stephanie Neil, MA senior editor


Need help in this rapidly changing economy? Progressive Manufacturing Summit 2009: Redefining the Business of Manufacturing in Turbulent Economic Times is an invitation-only event for senior-level manufacturing executives, providing you with the opportunity to gain insight and expand your knowledge, network with your peers, and walk away with a tangible action plan to address the toughest economic environment we have seen in years. Register Now.

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Is China Still King of Contract Manufacturing?

We’re at what I think is a pivot point for Chinese manufacturing. A number of factors are coalescing toward change, and the global economic blackout might just push things over the edge. 

For years, manufacturers in the U.S. and abroad have ordered a steady stream of goods from China’s voluminous product catalog, all the while swallowing the associated risk — speed to market, quality assurance, intellectual property breaches. One of the headings in a new AMR Research report, “Supply Chain Risk 2009-2009,” states it plainly: “China is the world capital of supply chain risk.” While the authors temper that assessment by noting that it may be inevitable, since China is enormously popular for outsourced production, the risk profile is well-established. The report continues:

China stands completely alone as a source of risk for IP infringement. It also leads prominently on both internal and supplier quality failures as well as security breaches. The message to companies with significant shareholder value resting on patents, designs, brand image, or other pure IP is that China may not be worth the risk.

That decision seems to be on hold, for now. Recessions have a way of turning people, companies, and countries insular, and, as such, you haven’t heard much about the China question lately. We all have our own troubles to deal with. Even in an interdependent world marketplace, most states are left to tug on their own bootstraps, with varying degrees of desperation and efficiency.

Like its counterparts around the globe, the Chinese government has dipped into its gi-normous wallet to fund the country’s recovery through stimulus spending, lending  vast reserves of money in an effort to resuscitate commerce. What I don’t see is a concurrent focus on changing China’s fundamentals, including improving quality and protecting intellectual property. If left unattended, those risks eventually will overshadow the allure of cost savings.

I’ve always thought of low-cost manufacturing destinations in the same vein as heavyweight boxers — no one holds the title for long. Is it time for China to relinquish the belt? If so, to whom?

Let us know what you think — add a comment below.

— Chris Chiappinelli, Editor, ManagingAutomation.com


Need help in this rapidly changing economy? Progressive Manufacturing Summit 2009: Redefining the Business of Manufacturing in Turbulent Economic Times is an invitation-only event for senior-level manufacturing executives, providing you with the opportunity to gain insight and expand your knowledge, network with your peers, and walk away with a tangible action plan to address the toughest economic environment we have seen in years. Register Now.

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SAP’s ‘Cloudy’ Outlook

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The Power of Crowds

I had a very interesting meeting at SAP’s Sapphire user conference last week in Orlando. Arranged by SAP Executive Vice President Zia Yusuf, I was introduced to a company called InnoCentive, whose mission in life is to help companies and other organizations innovative.

Now, the interesting thing about InnoCentive is that its business model is built around the idea of what it calls “challenge-based” innovation. InnoCentive attempts to leverage what it claims is the world’s first “open innovation marketplace” of 160,000 people from a multitude of businesses, disciplines, and professions to solve problems.

The company issues a challenge over its network, and the person who solves the problem is rewarded a financial prize. Dwayne H. Spradlin, president and CEO of the Waltham, MA-based firm, says cash prizes range from a few thousand dollars to $1 million. InnoCentive recently became an SAP business partner.

The company posts challenges in such disciplines as computer science and IT, engineering and design, life sciences, the physical sciences, chemistry, and other areas. Some current challenges in the engineering and design category are: quality control of plastic welding, with a prize of $100,000; a thermal protection system for the nose cone of a rocket, $10,000; and a selective biocatalytic hydroxylation process, $150,000.

I find InnoCentive a fascinating attempt to leverage the power of collaborative networks of people on a grand scale. Check out more at www.InnoCentive.com.

—David R. Brousell, MA Editor-in-Chief


Need help in this rapidly changing economy? Progressive Manufacturing Summit 2009: Redefining the Business of Manufacturing in Turbulent Economic Times is an invitation-only event for senior-level manufacturing executives, providing you with the opportunity to gain insight and expand your knowledge, network with your peers, and walk away with a tangible action plan to address the toughest economic environment we have seen in years. Register Now.

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Safety in Numbers

I attend a lot of software vendor customer conferences, and I’m often surprised at how flaccid and complaisant many supposedly independent user groups are. Rather than aggressively representing the rights and interests of user members, user group leaders often seem more interested in getting their smiling pictures taken onstage with the vendor’s CEO.

I understand why this is. Top user group officials are usually volunteers with real and demanding day jobs, and many seem to get involved with user groups more for the networking opportunities than for hardcore advocacy.

Still, as SAP’s recent experience with its user groups over software maintenance pricing makes clear, these days such groups have a real and important role to play in keeping software vendors honest and focused on the legitimate needs of their customers.

In the SAP case, the Americas SAP Users’ Group and other groups around the world got actively involved after many customers complained about SAP’s announced plan to raise software maintenance prices from 17% to 22% over a number of years. Rather than shrugging and smiling for the cameras, many SAP user group officials went to work to understand the concerns of their members. Some even went public with their objections. SAP UK & Ireland User Group Chairman Alan Bowling, for example, used his blog to question SAP’s move.

User group officials also worked with SAP, and last week produced an agreement that might just pay off for SAP customers. The apps provider and a dozen or so user groups agreed to a benchmarking program, based on mutually-agreed-to key performance indicators, intended to prove or disprove SAP’s claim that its new Enterprise Support offering will deliver benefits commensurate with its planned 30% price increase. As part of the agreement, which I understand was personally approved by SAP co-CEO Leo Apotheker, SAP won’t enforce the price increase if it can’t demonstrate the promised value. The company also said it would delay imposition of the full 22% maintenance charge.

Make no mistake, this is not a PR stunt. User group officials will be involved in the benchmarking, which will be validated by an independent (though unidentified) third party. There’s no guarantee that SAP will be able to clearly demonstrate a 30% value increase from Enterprise Support.

Whether or not it does, however, one thing has already been clearly demonstrated: The power of user groups that are engaged, truly independent, and not in it just for the photo-op.

—Jeff Moad, MA Executive Editor


Need help in this rapidly changing economy? Progressive Manufacturing Summit 2009: Redefining the Business of Manufacturing in Turbulent Economic Times is an invitation-only event for senior-level manufacturing executives, providing you with the opportunity to gain insight and expand your knowledge, network with your peers, and walk away with a tangible action plan to address the toughest economic environment we have seen in years. Register Now.

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The American Car Crisis, to Be Continued…

I just finished reading the transcript from yesterday’s White House press briefing on the auto industry — namely, Chrysler’s fate. I have my own opinions on the government stepping in to save American car manufacturers, but I’m not going to blog about them.

Instead, I’m going to focus on the “innovation” element of “The Plan.”

The government is forming an alliance with   Fiat, under which the Italian carmaker will initially get 20% of Chrysler, then additional 5% increments each if it achieves these milestones:

  1. It provides distribution for Chrysler cars outside the NAFTA region.
  2. It brings production of new fuel-efficient engines to a U.S. Chrysler factory.
  3. It introduces a 40-mile-per-gallon car, also made in a U.S. factory.

Fiat has advanced engine technology, which is what the government is after. Here’s a direct quote from the transcript:

“But it’s Fiat’s technology, which experts value at many billions of dollars, which will enable Chrysler to very quickly move up the curve and introduce these new engines and these new cars, which otherwise Chrysler would not have been able to do without years and years of additional work and billions of dollars of development cost,” said a senior administration official during the press conference call.

Gaining access to that engineering expertise is a nice feather in the cap, for sure. But how is Chrysler going to build an eco-friendly car without also conducting a major overhaul of U.S. factories? One hopes that, too, is part of “The Plan.”

Technology advancements go beyond product R&D. In order to move Chrysler into the competitive category, the government — or Fiat — better be ready to fund some automation and infrastructure upgrades.

One can see the lack of investment by way of companies such as Rockwell, which have deep roots in the U.S. automotive industry — although it and many of its peers have lately moved into process sectors. This group of technology providers has suffered as a consequence of its ties to Detroit.

In fact, when Rockwell announced its Q2 fiscal results earlier this week, chairman and CEO Keith Nosbusch was asked if GM factory shutdowns this summer would impact Rockwell’s numbers further. He replied: “The bigger impact will be how Chrysler and GM come back as entities … That will have a bigger impact than … the shutdowns.”

And, hopefully, a positive impact all around.

—Stephanie Neil, MA senior editor


Need help in this rapidly changing economy? Progressive Manufacturing Summit 2009: Redefining the Business of Manufacturing in Turbulent Economic Times is an invitation-only event for senior-level manufacturing executives, providing you with the opportunity to gain insight and expand your knowledge, network with your peers, and walk away with a tangible action plan to address the toughest economic environment we have seen in years. Register Now.

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