Category Archives: Manufacturing & Operations

How Do You Downsize Intelligently? Three Perspectives

Situation: A company has run into a rough patch and needs to cut costs. The CEO is considering a number of alternatives, but wants to hear input from other CEOs on how they have faced this challenge. How do you downsize intelligently?

Advice from the CEOs:

  • The key to intelligent downsizing is to take a different perspective. Look at the needs of the business in terms of a 3-5 year plan, not just at what is needed to do to survive today.
    • What key talent will be needed 3 years out? What key roles will need to be filled? Who is on-board today who will be needed in 3 years? How does this affect the decision on where to trim? Are there other options to simply laying off staff?
    • Answering these questions helps to consider options with a rational long-term view.
  • Establish a new paradigm. What do you want the business to become?
    • Is it the same as, complimentary to, or completely different from the current business model? Once the paradigm is developed plan personnel needs in line with this paradigm.
  • Look at all resources proactively.
    • For example, if you are considering moving your offices to a smaller space, look at your vision for the company 3 years out.
    • It may be more sensible to stay where you are and negotiate a new lease with your landlord that is more favorable short-term than paying for multiple moves.

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How Well Do You Know Your Target Audience? Five Points

Situation: A CEO and her team manage a growing and profitable company. She is interested in what others have done to expand their market presence and penetration. In discussion, other CEOs have been curious about her company’s marketing capabilities, and how well her team knows their customer base. The essential question that they ask is “How well do you know your target audience?”

Advice from the CEOs:

  • Become a thought leader:
    • This is Inexpensive because the company is already a leader in its field.
    • Marketing through thought leadership allows the company to get its message out with fewer resources than push marketing efforts.
    • Thought leadership adds credibility and educates the customer.
  • Qualify the need and/or the perception of the need. If there is no need, there is no sale.
    • It’s perfectly acceptable to ask clients about their challenges and needs.
    • Ask them to measure the need on a 1-10 scale.
    • Ask the client to play out the scenario without an adequate solution.
    • Ask the prospect how they have worked with others offering similar services to your company’s and how did that go?
  • Ask your customers to help.
    • Develop a Customer Advisory Board to test a new product or concept – a “Blue Ribbon Panel”.
    • Write a paper together with them to highlight the findings.
  • Use common sense, but:
    • Set measurable goals and listen to enough people to get more directed feedback.
  • The company’s internal staff is also a target audience.
    • Integrate departmental cultures to assure that they don’t clash.
    • Conduct collaborative off-sites to encourage cooperation and support.
    • Create processes for all departments and staff.

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How Do You Reduce Risk When Outsourcing? Three Points

Situation: A CEO is looking at an outsourcing opportunity in Asia. If a suitable partner is found, this will be the company’s first experience with outsourcing. What is the experience of others who have outsourced either parts or assemblies to a foreign supplier? How do you reduce risk when outsourcing?

Advice from the CEOs:

  • Outsourcing to a foreign supplier is not low risk.
    • Find another CEO who has experience in outsourcing.
    • Consider hiring a consultant who specializes in foreign outsourcing.
    • Once a promising opportunity has been identified, select and put in place a trusted individual on-site who can stay abreast of developments and issues and who can alert the company on both potential opportunities and problems.
  • Execute key initiatives by treating this opportunity like a customer’s project.
    • Prioritize.
    • Set project time in percentages or dollars.
    • Allocate an appropriate budget.
    • Institute an appropriate job/project tracking system for outsourced projects.
    • Hold people just as accountable as if this were a project for a customer.
    • The internal “customer” should be just as demanding as an actual customer.
  • Reduce the risk in staffing.
    • Identify requirements.
    • Agree on expectations, then delegate and trust.
    • Two way communication is critical.

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How Do You Foster Productive Communication Within Your Company? Six Suggestions

Situation: A CEO is concerned that communication between employees is often non-productive. Individuals can be abrasive in their comments. This leads to loss of productivity because the individual criticized feels hurt and distracted. It also results in the formation of “subgroups” which conflict with each other. How do you foster productive communication within your company?

Advice from the CEOs:

  • Encourage tolerance of and sensitivity toward individual styles.
    • Identify the particular style of each individual. Assessment tools are helpful.
    • Admit that different individuals have different styles and that this is OK. Have a conversation with them so they are aware of this.
    • Always allow an individual one “charm” that is uniquely theirs.
  • Identify the motivations that drive each individual within the company.
    • Communicate with each individual in a way that recognizes and aligns with their motivation.
  • Focus on constructive communication aimed at helping the individual to strengthen performance. Build a foundation of fact to reduce the risk that what is said will be taken personally or interpreted as critical. Become the model for how others can effectively communicate with each other.
  • Meet others half-way.
    • Outline, test and agree on basic assumptions to get the conversation rolling.
    • Weigh the pros and cons of each suggested alternative.
  • Use employee reviews and compensation decisions as motivators.
    • Explain the company’s marketplace and plans vs. market practices. Get the facts. Know what each job typically pays and market balances between salary and incentive compensation.
    • Align the rewards offered with each individual employee’s motivations.
    • If an employee is not a 5 (on a scale of 1 – 5), explain what they need to do to become a 5.
  • Keep the annual retreat alive when everyone returns to the office.
    • Generate follow-up plans as part of the retreat. Include measurable objectives, responsibilities, accountabilities and timelines.
    • Identify solutions, not just problems.
    • When asking for recommendations, acknowledge each suggestion. Be prepared to implement what is suggested – in whole or as part of a larger strategy.
    • Recognize that the environment is in constant flux and that the company must continually adjust to adapt to changes.

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How Do You Negotiate the Purchase of a Franchise? Seven Points

Situation: An experienced CEO is considering the purchase of a franchise. What are the key points to consider in both evaluating the opportunity and in negotiating the purchase? What advice should be sought? How do you negotiate the purchase of a franchise?

Advice from the CEOs:

  • Most franchises have a set contract in use by all of their franchisees.
    • Ask for the names of existing franchisees and ask them what works or doesn’t work both about their contract and the services provided by the franchisor.
    • Ask the franchisor whether they will agree to a side letter to cover areas of importance outside of the franchise agreement.
  • What services and are offered by the franchisor as basic infrastructure and what are offered as a percent of sales or other fee arrangements?
  • Look closely at the frequency and amount of franchise fees. What fees are set or variable? What is non-negotiable?
  • Is there a need for a professional to represent you as the buyer?
  • Closely inspect the prospectus financials – franchisors in many states are required to provide these to prospective buyers. What is the initial investment? Are there monthly or periodic minimums to be paid by the franchisee? What are typical monthly operating costs.
    • Add to these your salary replacement costs – assuming that you will have to pay yourself something over the break-even period.
    • Calculate the monthly revenue needed to break even, and to pay off the initial investment.
  • Evaluate the competitive situation facing the product/services offered by the franchise. Network with others in the market to assess both the market potential and any barriers that that will be faced as the franchise is established.
  • What other questions should be asked?
    • Why is this business interesting?
    • What is your experience and what is the experience of the franchisor?
    • How well do you understand the market that the franchise will be serving?
    • What does the franchisor bring to the table that you cannot do yourself? What are the comparable costs?
    • What is the anticipated rate of return? How is it being calculated? Can this be verified with third parties?
    • What criteria are deal makers and which are deal breakers?

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How Do You Position a Company for Value and Growth? Six Points

Situation: A CEO wants to set up her company for long-term growth in value. The business has favorable margins relative to competitors and high cash flow. It is currently single-site but has a good model that could be expanded to multiple sites. How do you position a company for value and growth?

Advice from the CEOs:

  • Paint a picture of growth and cash flow. Use this picture to inspire both the home site and remote sites as they are developed.
  • Develop and demonstrate a Growth Model. It is important to demonstrate the success of the model so that it can be replicated in remote locations.
  • Get multiple sites up and running as proof of a profitable growth model.
  • As the company moves to a multi-site model, assure that each site manager has a financial interest in the success of the site. Develop a compensation system that rewards the manager for both growth and profitability. Develop a complimentary system that rewards key site personnel.
  • Develop additional products and accompanying services. These can be sold to current customers as well as new customers at the home and remote sites to boost growth.
  • As the model grows use the improved cash flow to buy other companies that are complimentary or expand the capacity of the existing company.

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How Do You Manage Major Projects? Seven Points

Situation: A company conducts both engineering feasibility studies and development projects. These are high budget projects and must be managed diligently to prevent cost overruns. What have others done to assure that projects are planned and managed to budget? How do you manage major projects?

Advice from the CEOs:

  • What is the structure of most contracted projects?
    • Most projects are fixed price. They come from feasibility studies which are essentially “marketing” for future sales. Typical terms are 30% up front, with the other 30/30/10 upon achievement of milestones and completion of the project.
  • Get complete buy-in from the customer as part of the initial negotiation.
  • Stay ahead of expenses by billing in time to maintain positive cash flow from the projects.
  • Structure pricing so that custom work is profitable if the project mix is 50/50 custom vs. standard work.
  • Push-back if the customer wants to reduce project cost up-front.
  • Carefully document work papers – above what is required by the contract. Get buy-in for this in advance, during the initial negotiation.
  • Once the feasibility study is completed, revise the scope and deliverables of the work agreement based on findings from the study.
  • Separate the “concept” phase from the execution phase and charge a premium for the concept work.
    • Position this as a value to the customer.

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How Do You Take on Additional Business When You Are Capacity Limited? Seven Suggestions

Situation: A Company has been growing rapidly over the past year. This has strained resources in some departments, including manufacturing. New customer demand just keeps coming in. What can the CEO do to meet customer demand without busting at the seams? How do you take on additional business when you are capacity limited?

Advice from the CEOs:

  • There are three questions to be asked before taking other steps:
    • Is it possible to expand manufacturing by outsourcing?
    • Can the company just hire more people?
    • Is the business that the company is getting good profitable business?
  • First, what a great problem to have – not to belittle the challenge that the company faces.
  • If there is concern about the company’s vulnerability to future downturns and the company is holding off adding staff because of this, look for a filler product that can help the company to smooth business cycles.
  • Farm out constrained work to other departments of the company – for example engineering. Are there independent entities that the company could partner with to add temporary capacity?
  • If there are financial constraints, then look at adjusting the pricing for new business.
  • If there are conflicts between capacity in manufacturing and engineering, consider becoming more of an engineering-focused firm and invest in this area. Look at outsourcing manufacturing capacity.
  • Look for sources of temporary capital to fund the company through the adjustment. Use an existing bank line of credit or a loan to finance short-term capital needs.

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How Do You Preserve Exit Strategy Value as a Minority Owner? Five Points

Situation: A company has been in business for 38 years. The majority owner founded the company. One of two minority owners has obtaining her share position through sweat equity. Another minority owner is on the Board but is not involved in the day-to-day operations. There are buy-sell agreements in place to preserve the interests of the three owners. In the case of an exit how do the minority owners preserve the value of their shares of the company? How do you preserve exit strategy value as a minority owner?

Advice from the CEOs:

  • Details of the current arrangement:
    • All partners are currently capped at 33% ownership.
    • The expectation is that in 10 years the two minority owners will buy out the principal owner and split ownership between themselves.
  • It is far better to negotiate potential ownership position up front – at the time of entry into a business, rather than along the way. As this apparently was not the case the minority owner has two points of leverage:
    • The minority owner has a good relationship with the principal owner, a very important factor, and the owner cares about the minority owner.
    • As the minority owner develops a track record of success, this should be leveraged in addition to the relationship to assure that the interests of the minority owners are preserved.
  • Additional key points of leverage of the minority owner asking the question:
    • The option to walk away as principal manager of the business if not happy with the situation.
    • Upside value of the company.
    • The desire of all owners to maintain their current life-styles, which are dependent on income from the business.
  • Separate management and control of the business entity from day-to-day operations. These are distinct and different areas of focus.
  • Another option to consider is the use of insurance policies to fund a buy-out of the majority owner.

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How Do You Fund Growth Strategically? Five Approaches

Situation: A CEO is looking at a significant investment in capital equipment. Being considered are not just the cost of the investment, but the opportunity cost of not making the investment and the impact that this will have on the business. An additional consideration is the business mix of the company and whether to shift focus from low volume/high margin to low margin/high volume products. What tools have others used to assess these trade-offs? How do you fund growth strategically?

Advice from the CEOs:

  • Review the company’s approach to contracts. It may be desirable to revise the approach in light of the new objective. The switch from low volume/high margin to low margin/high volume products impacts not only production but also marketing, sales, finance and accounting.
  • Price some early new contracts below market to finance the additional equipment expenditures, as well as to test market response to the new offering. This will help to identify additional adjustments that are needed for the new approach and offering to succeed.
  • Structure the financing options for equipment purchases creatively, for example by allowing for participation by customers and investors.
  • Watch changes in working capital at all times and keep it under control. Working capital is a commitment of resources just as is buying equipment or facilities.
  • Consider all resource commitments as investments, regardless of the way the accountants deal with them as in expensing vs. capitalizing these investments on the balance sheet. For example, a marketing program is an investment even though it will show up as an operating expense. Make sure that this can be justified in terms of future cash flows expected.

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