Category Archives: Manufacturing & Operations

How Do You Scale Up a Product That Is Taking off! Four Points

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Situation: Demand for a product produced by a company has increased dramatically. The CEO realizes that they need to scale up production quickly to meet this unexpected demand. The company is small and the CEO wants advice as to how his company can accomplish this without killing the product. How do you scale up a product that is taking off?
Advice from the CEOs:
• This represents a major change of both mentality and culture. Essentially, the company needs to move from a “handmade” process to a commodity volume process. This may also mean moving from low volume/high margin production to high volume/lower margin production. This shift will significantly change the company.
• If there is high confidence that the company will land a contract for long-term production consider establishing high volume production at a new site. Rent or lease another facility. Alongside this hire a set of experienced people who understand the challenges of scaling up rapidly. Consider giving this facility a new name to suit the new team. This will help to establish a new culture suitable to the new opportunity.
• While negotiating a lease, ask for an option for additional space to be included in the lease. If things don’t pan out, look at this new space as the eventual location for your existing team.
• Two other options to consider: (1) Outsourcing to a 3rd party manufacturer. This is an option unless the company is an OEM outsourced producer itself. However, be careful – you could be telling your customer that they could go directly to your OEM source at a lower price. (2) Establishing an overseas production capability – one where you own the facility and manage quality control. This will be a challenge if the customer wants to specify “Made in US”, or where quality concerns are essential.

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How Do You Replace a Key Position? Four Points

Situation: The CEO is moving a key employee from head of engineering to a more customer development focus. To support this, she will have to bring in or promote another employee to fill the position of leader/supervisor/manager of the engineering group. The CEO seeks advice on the best way to approach finding a replacement for this key job. How do you replace a key position?
Advice from the CEOs:
• First, it is necessary to develop a timeline for finding and transitioning the replacement. Realistically, count on 6 months to find a replacement and transition the responsibilities to a new person.
• Keep in mind that anybody you find or promote will be different from the individual who currently occupies the position, and will not handle their new responsibilities the same way as the current individual. Their motivation and their approach to their new responsibilities will be different, at least at the outset, and they will not handle their responsibilities the same way that the current individual does.
• Seek an individual, either currently within the company or an outside hire with strengths that, over time, will add significant value to the organization. Prepare for this by brainstorming and developing a profile of the ideal candidate.
• If you have qualified candidates, the ideal person will come from within the organization. This has the added advantage of demonstrating to other employees that they, also, may become candidates for future positions to grow both their skills and income.

How Do You Purchase a Company as a Non-Owner President? Four Points

Situation: The President of a company has a long-standing relationship with the Chairman and Founder, who is also the principal owner of the company. The President joined the company at a time that the Chairman/Owner thought that he was terminally ill and needed an individual who could take over operations as well as leadership. Since then the owner has fully recovered and wants to retake control. The President would like to buy out the owner. How do you purchase a company as a non-owner President?
Advice from the CEOs:
• What role has the President played so far? The President has advised the Chairman on how to grow the company and is leading this growth through developing key customer relationships.
• What is the owner currently doing? The owner has fully stepped back into his prior role, and is micromanaging all aspects of the business, effectively shutting out the President.
• The best way to avoid a situation like this is to negotiate the full deal, including transition of authority and terms of transition of ownership, up front before the signing of an employment contract. Not having not done this, the President currently has no leverage.
• The best option at this point is to have a conversation with the owner and to see whether the owner is open to a transition of either power or ownership. If the owner is not interested, the President may want to consider other opportunities.

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How Do You Expand Your Market? Five Suggestions

Situation: A CEO’s company has historically been organized around a single company’s products and technologies, though their customer base uses multiple platforms. The company wants to expand from a single-technology emphasis to a broader technology base which will more accurately reflect its customer base. What can assist the company in building both its technology and customer base? How do you expand your market?
Advice from the CEOs:
• Conduct surveys among users and employees of the existing customer base. Use what is learned to design new approaches to expand both the company’s technology base and customer base.
• Expand into additional industries, products, and a more diverse company customer base.
• Determine to there is a genuine need for the company’s technology and services. If not, adjust both the technology and offering to better meet customer needs.
• Build a marketing campaign around differentiating factors that others do not provide. For example, in the cooperative banking industry market accounts that allow no-fee ATM access through other coop networks’ and banks’ ATM machines to expand customer convenience and appeal.
• Target niches. For example, small businesses or home businesses where the company’s lower fees make a difference and personal service is appreciated by the owner or someone who works closely with the owner.

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Why Do We Keep Trying to Grow? Three Thoughts

Situation: A CEO is looking at the strategic plan of her company. They are planning for growth but a question arises – what is the balance between work for the sake of the work and work for the reward that it brings? What are the thoughts of the other CEOs around the table? Why do we keep trying to grow?
Advice from the CEOs:
• Step back and ask – what do I seek? Do the same with the members of the leadership team – what do we seek?
• Define what you want and what enough is. There is always the question of whether when reaching the goal will it be enough? Work with your team to discuss and seek a consensus on what their objectives are both for themselves and the company. You may be surprised at what this discussion yields. Two books may help you to deal with this question: The Gap by Dan Sullivan which deals with growth, motivation and satisfaction and Small Giants by Bo Burlingame of Inc Magazine which tells the story of a number of companies that decided that growth is defined by the impact that they have on their employees and communities as opposed to growth in revenue or profits.
• Repeat this discussion with the team at least annually. Expectations develop and change over time. An annual review of plans and opportunities empowers the team to make interesting and valuable contributions.

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How Do You Forge an Effective Relationship with a Buyer? Five Points

Situation: A CEO’s Company was recently acquired. She is getting little, if any, guidance from the acquiring company in terms of leadership or management of her former company. What does the group recommend that she do? How do you forge an effective relationship with a buyer?
Advice from the CEOs:
• You’re Lucky: We all wish we had that problem. Many buyers interfere with the operations of the acquired company and make the transition very difficult. This leads to all sorts of problems including employee departures.
• Employee Feedback: Hold an employee meeting, gather their thoughts and concerns, forward those to senior management. This demonstrates a willingness to work with the buyer to forge the best relationship possible.
• Memo: Draft a memo with all of your thoughts, options, and recommendations, send it to the management of the acquiring company and you have satisfied your moral responsibility. No guilt.
• Consult: You may end up consulting to new management sent to you by the buyer to help them figure out how to evolve from practitioners/managers to full-time managers.
• Don’t Worry: The purchase was a good deal to you because you were able to negotiate a favorable deal for yourself and your managers. The future is more a concern for the purchaser than it is for you.

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How Are You Preparing for Next Year? Two Approaches

Situation: A CEO and his team are preparing for next year. There is a lot of uncertainty as to how the year will unfold and what the economic and financial environment will look like. What are others doing to plan for next year and beyond? How are you preparing for next year?

Advice from the CEOs:

One company built a 5 year plan to 2028 about a year ago.

    • They are now reviewing the plan. Their core has been growing faster than anticipated as a result of the new sales effort. For next year and beyond they are revisiting the plan and revising it both to take advantage of the new sales effort and to leverage this success into other areas.
    • Within the plan, priorities for growth have been identified, and the company is on target to double the size of the company in 5 years.

Another company established a Strategic Priority Team a few months ago.

    • They started by setting goals for 2025 to 2030. They followed this with a plan for what they need to do year by year until 2030 to realize this plan. They recognize that there may be speed bumps along the way but have established the internal discipline and capacity to address these.
    • Within the plan, they are looking at expanding ther facilities in 2nd half of 2026, and plan to double both their space and staff over the planning period.
    • An additional area where they will focus is their current and new business development effort.

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How Do You Frame a Make Versus Buy Decision? Two Thoughts

Situation: A CEO is facing a decision whether to make or buy key technology frequently used by the company. What have others done when faced by similar decisions? What are the most important factors that impacted those decisions? How do you frame a make versus buy decision?

Advice from the CEOs:

  • In considering either option evaluate the opportunity by asking whether the technology:
    • Complements the company’s core strategic focus – the company’s “Main Thing” – what you are passionate about, what drives your key economic denominator, and what can you be best at in your market.
    • Supports the key economic denominator – the single factor that has the greatest impact on the company’s profitability and growth.
    • Complements the best use of the company’s critical resources.
    • Protects the company’s process secrets.
    • Feeds your passion as CEO.
  • In evaluating a buy decision look at the strengths of the people who come along with the opportunity.
    • Do they complement the company’s strengths or not?
    • Will they fit the company’s ecology and culture?

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How Do You Correct Inappropriate Behavior of a Productive Employee? Four Points

Situation: A CEO has a key manager who frequently uses inappropriate language and demonstrates lack of care towards co-workers. This individual is smart, has great drive, and does the work formerly handled by two employees. How do you correct inappropriate behavior of a productive employee?

Advice from the CEOs:

  • Create a firm company policy on swearing and the use of inappropriate or abusive language.
    • Each time any individual swears or uses inappropriate language, they must put $1 into a pot. Anybody can call anyone else for swearing and the one who’s caught has to pay. The money in the pot goes to buy pizza on Fridays.
    • This is a creative and even entertaining solution and should resolve the problem in a short time.
  • Sit down with this individual and go over their positives and value. Besides these, emphasize which behaviors are unacceptable.
    • Explain the legal implications and consequences for the individual and company. Provide goals and set objectives.
  • Send this individual alone or with a team to a Pryor Customer Relationship seminar, for example the seminar “How to Communicate with Tact and Professionalism”.
    • Let the instructor know in advance that you want to be sure that certain behaviors are covered during the seminar.
    • This may provide the individual the incentive to behave like an owner of the business.
  • Make it clear who’s in charge, and at whose discretion the individual remains with the company.

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How Do You Focus Your Team? Six Points

Situation: Several CEOs asked how others have had success improving company performance and is interested in how they focused their teams. How do you focus your team?

Advice from the CEOs:

  • Important tasks for any company are to validate the value proposition, technology, target customer, and the rate of market expansion, and minimize risk and liability. This should be a regular company exercise – not a one-time event.
  • Assuming that a company has goals and people who can align with and achieve them, a company needs a vision – the broader strategic picture of where they are going. Often some of the best ideas come from line staff who are enabled by their company’s culture.
  • It is critical that companies are able to quickly identify problems and have systems in place to drive problem resolution. The minigame technique is very useful in these cases.
  • Companies should have a plan for transitioning employees into new roles as the company grows. The key is clear identification of the individual’s role within the company, and how that role compliments achievement of company objectives.
  • If a company wants to grow sales from, say, $20 to $60 million, it will need a professional sales leader. In addition, growth may require a change in company culture from engineering and development centric to sales centric.
  • A significant challenge is determining how to define corporate success. Much depends upon the questions asked. The Great Game of Business by Jack Stack provides guidelines and tools for assessing options. Anyone starting or growing a business should look at this book.

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