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If 2018 hasn’t gone fast enough for you, the holiday season is upon us and like every holiday season, nothing is ever easy! This year there are a number of potholes that are appearing on the road to the holidays and beyond, and if you have not already prepared for some of them you might find yourself celebrating without any “roast beast” this year!

Last week we talked about a few common myths regarding Quality Control (see “5 Myths About Quality Control”), but one myth we did not cover was the one about Quality Assurance being the same thing. It’s not uncommon to hear them used interchangeably, and in a closed-loop environment of a large facility, it might not make a difference if everyone agrees to what the definitions are in their environment. But if you ever plan to use outside resources in any way, or want to make sure you are on the same page with suppliers and customers, it might be a good idea to understand the differences and apply them accordingly.

While there is generally NOT any disagreement about the need for quality control, there are definitely different levels of appreciation for it and commitment to it. No manufacturer would want to admit to not having a quality control process, and we assume that it would be rare to find any that don’t. However, there are a lot of myths about the topic which permeate perhaps because they work as an excuse for not doing things to the level the business should be – or is capable of. Change is hard, but the myths make it harder.  Here are five of them we dispel here today.

What kind of facility looks like a factory but isn’t? Or looks like a warehouse, but looks far more industrial than a typical facility with racks principally designed for storage? The “Added-Value Warehouse” is something of a hybrid. It is a facility that does some additional work on a product before it ships out rather than just storing, picking, packing and shipping previously finished products.

Staffing, employee retention, and productivity are hot topics during an economy with a low unemployment rate of 3.7%. In August we shared the benefits of Big Ass Fans, and in July we shared how to reduce employee turnover and improve productivity.

Last month, we published Part I of this article, where we talked about making that transition from “freewheeling inventor” to “process-driven listener”. Basically, it is about being more systematic in how you collect the data and insights that lead to more relevance in your new products. This is hardest for the business which was started from a single brilliant idea that succeeded, because it is not uncommon for the small manufacturer to not really understand WHY their initial product succeeded. Play-Doh, the ubiquitous colorful molding clay of everyone’s youth, was originally created in the 1930’s as a wallpaper cleaner. Success is great, but if you started out intending to be an innovator in the cleaning products business but all of your customers are under five years old, where do you go next?

Over the years you’ve seen a lot of material coming from us about using “Lean” Manufacturing and using Lean techniques in other areas like distribution and logistics. As a manufacturer ourselves, we have always strived to take our own advice, but like many of you, we also learned in the process that while the reward is great, the work to get there can be HARD.

With inventories bulging from summer shipments coming in for the holidays, Distribution Centers everywhere are gearing up for the peak retail season. Historically the last four months of the year generate about 60% of a typical retailers’ annual sales, which also means this is the season where many businesses earn their real profit for the year. But how do you make sure all that inventory get out the door as planned and you are not stuck with overstock at the end of the year?

With heightened competition from the global economy, a dwindling workforce as a result of the labor shortage and increasing demands from customers—it’s never been more important for manufacturing facilities to focus on efficiency. Of course, many operations managers turn to lean techniques in an effort to streamline and increase production, but how can facilities take things a step further? 

If you’re like many small manufacturers, you started your business in one of the following ways:

1. You saw a gap and had an inspired idea that you turned into a successful product
2. You worked for another manufacturer and saw a better opportunity to become their supplier.
3. You cashed out of your first career success to fund your dream startup.

And if you are a 2^nd or 3^rd generation business owner, then your family likely started one of those ways too, and they did well enough to make it successful for over a full generation.

Regardless of how you started and what you started with, everyone has the same problem: