Manufacturing Software Efficiency Requires a “No-Slop” Culture

 

By Mike Hart

 

If you have a small manufacturing business and you wish to boost your efficiency using a manufacturing software package, you have no chance of success unless you adopt a “no-slop” culture among your users. 

 

My company, DBA Software Inc., has been a developer of manufacturing software for small businesses since 1992.  Over the years we have seen many companies achieve dramatic efficiency gains, while others fail to get results or give up on the software altogether. 

 

Among the companies that fail, upon investigation we invariably find that there is little respect for the accuracy of the “inputs” that drive any manufacturing system.

 

What are these inputs?  Specifically, I’m referring to BOM and job specifications, sales order due dates, job scheduling dates, and stock counts. 

 

Manufacturing software is dumb, in the sense that it has no ability to make judgments or interpretations like a human being can.  Inputs are taken literally, so when a sales order due date is given, the planning system schedules jobs to be completed by that date.  If a bill of material calls for certain components, the planning system sets in motion POs to have those components on hand when needed.   If the system sees that stock is not on hand, the planning system will seek to replenish that stock. 

 

So without accurate inputs, you have “garbage in, garbage out” syndrome such that the system cannot function efficiently. 

 

Input accuracy is beyond the control of the software.  It can only be achieved through the creation of a “no-slop” culture where there is zero tolerance for sloppy processes and procedures. 

 

In a no-slop culture, users establish and maintain accurate dates, are committed to maintaining accurate BOM and job specifications, enter transactions in real time, and faithfully adhere to processes and procedures. 

 

When you hear a business owner make comments such as “our people can’t possibly maintain accurate bills of material” or “our workers could never handle a location based inventory system” or “our workers don’t read and can’t be expected to do paperwork”, you know the company is loosely managed out in the shop.

 

Sloppy environments are common, especially when companies start out small and lots of things can be kept in people’s heads and done informally.  But you reach a point in your growth when inattention to detail becomes a real drag on your efficiency. 

 

Many companies compound the problem by attempting to implement a manufacturing system as the “cure” for efficiency woes, instead of addressing the culture issue first.  Imposing a manufacturing software package on a poorly managed company may make that company worse off than it was without the software.    

 

Transforming to a no-slop culture is not easy.  Symbolic changes can be helpful, like in the movie when Patton took over in North Africa and required his soldiers to cinch up their ties, wear their helmets, and stop putting cigarettes out on the floor.  You may have to take similar measures to instill a sense of discipline in the shop.  Veteran employees who cannot or refuse to change their ways may have to be let go for the good of the company as a whole. 

 

If you are planning to implement a manufacturing software package, take a sober and objective look at your company culture and make sure that your users are prepared to operate within a no-slop environment.  If not, I suggest you put your plans on hold. 

 

If you have already implemented a manufacturing software package and you are operating in a sloppy environment with poor results, it is imperative that you take immediate steps to create the no-slop culture that must be in place to achieve the efficiency gains that are possible with manufacturing software. 

 

 

Mike Hart is the co-founder and President of DBA Software Inc., a leading provider of manufacturing software for small businesses.

Comments

[software development in london]

That was inspiring,
Great information about Manufacturing Software Efficiency,
Thanks for writing about it

[Joe Urban]

Totally agree with your take on the "slop culture" evident in some businesses, and your reasons for self-implemented software. On my bussiness site I have included a free to use Productivity calculator (USA version also available) for individual companies to determine their current performance. My input notes also reiterate your comments above.

Good article

[bespoke software development]

Just come across this, but still just as relevant now, if not more so.