Is Lean Manufacturing the Answer to Outsourcing?

There has been a lot of push on the future of outsourcing lately, mostly looking at where it will stop or more importantly what happens when there is no more cheaper alternative for the global searcher. We have all seen it, product moves to country X, then as the standard of living rises there it moves to the next country that has a lower wage, and once it is done there it moves on. But once this phenomenon has swept around the globe what happens to a company that has not leaned out its process and was relying solely on the cheaper labor rate to make their product? The answer is they become extinct and the business goes to those companies with the more effective process. 

Lean manufacturing is the answer to outsourcing because while your competition is spending 10 million in capital investment to save 0.30 on each part in labor, your organization has avoided the 10 million expenditure, placed it into R&D and is still seeing a 0.30 savings as a result of driving the waste out of the part. This philosophy also makes good sense in terms of plant efficiency, efficiency rates in a green field operation usually are not up to the existing plant process standards until 18-24 months following the operation’s opening ( which can be years in construction), and subsequently if you can keep a high efficiency rate in addition to the same piece price cost then your savings is actually greater. This of course does not address the decision by an organization to outsource for market penetration as a strategic move, but the costs associated with the move become exponentially higher if the domestic operational unit has a good solid lean culture in place. 

In the end reliance on labor as a competitive advantage is a losing proposition for any organization, you will either fall victim to the slow bleed of inflation, the moving target of global currency fluctuation or may experience a major upset in the event of political instability within the region (volatile regions are those more prone to having lower labor rates). A continuous improvement culture is a sustainable cornerstone of your operational management strategy because innovation drives high profit, not replication of the same old idea. Outsourcing is all about cost reduction, if it wasn’t they would just open sales offices in the countries a business wants to move into. As a manufacturing unit the innovation in your processes will continue to make your operation a continued profit center, and no company will willingly close a high profit producing facility in favor of a potential green field operation that is several years behind an existing powerhouse. 

12 Ways to Reduce Costs in Business

SPECIAL GUEST BLOG By Sean Donnelly, Financial Management Mentor, Mentors.ie

The manner in which costs are reduced can either greatly help or seriously damage a business. Cutting the wrong costs or failing to reduce the appropriate

costs could endanger prospects for getting through the down-turn and the recovery prospects for a business. Irrespective of the organisation size the principles remain the same. The challenges for management are:

1. Not just about reducing costs in absolute terms but reducing unit operating costs.

2. Increasing efficiencies and competiveness.

3. Retaining the right staff and bringing the organisation with you.

4. Do it responsibly and with respect.

In summary there are at least 12 ways to reduce costs:

  1. The simple approach: Cutting all discretionary spending on advertising, recruitment, training, delaying payments etc. This approach is simple, direct & effective at stemming cash outflow quickly.
  2. "Bureaucratic" cost reduction: Centralised, imposed, rule-based cost control with strict budgetary controls.
  3. "Equitable" cost reduction: Setting cost reduction targets e.g. 10% for every department. This approach frequently brings out the "departmental/functional" mentality.
  4. "Stretch targets" – This is similar to the “equitable” approach but "stretch" targets means that the target varies by each functional area so that those areas where there is believed to be greater cost reduction opportunity can be asked to stretch towards a more demanding cost reduction target than other areas.
  5. "Sweat the assets" approach: e.g.. cutting debtor days, reducing stocks, selling assets, delaying supplier payments.
  6. Relocate: moving to a cheaper location.
  7. "Changing the way we do things": Reviewing and re-engineering business processes, reviewing the way we service customers, reviewing overhead and IT effectiveness.
  8. "Changing the mix of what we do": Trimming bad products/services, trimming poor customers, reviewing & changing routes to market & distribution channels, reviewing cost drivers. Activity analysis, data collection, challenging the way we do things are key steps of this process.
  9. Simplify/rationalise the company structure: Review the organisational effectiveness including delegation, accountability, job specifications and performance targets.
  10. Strategic purchasing – working with suppliers, buying smarter etc.
  11. Outsourcing.
  12. The strategic option – This incorporates all the proactive elements of the above including restructuring the company in line with a strategic plan to fulfil customers requirements.

Any approach focused taking only the first few steps alone will be unlikely to yield sufficient advantage over competitors taking a more strategic view. In summary, the most effective way to gain long-term advantage from a cost-reduction process is through squeezing all costs, eliminate all waste, changing strategic shape, playing to and building on strengths, maximising efficiencies from all necessary processes whilst eliminating unnecessary processes. A properly implemented cost-reduction programme offers a business a chance to re-position itself for a better future, re-focus on customer's real needs and to re-define how value is added.

The first step in increasing efficiencies is a thorough analysis of the role of all activities in the achievement of the strategic plan and of how value is created for the company & customer. Research suggests that c. 40% of operational expenses result from wasteful activities that add no value to the customer and therefore should be eliminated. There are 7 types of process waste that can be identified in virtually every organization: 1) Transportation. 2) Inventory. 3) Excess movement. 4) Waiting. 5) Over-production. 6) Over-processing and 7) Defects. Those activities that are not relevant can be eliminated or modified, thereby reducing costs, redirecting associated resources to more relevant tasks, and maintaining a high quality of service at the lowest unit and total operating cost.

Operations Management Opportunities to Avoid Outsourcing Impact

According to an exercise performed at Harvard business school in 2008 it is estimated that between 20-40% of the jobs that make up the Irish economy are able to be exported overseas. We review this exercise at this critical juncture because two years after this exercise the reality points to the accuracy of the exercise in light of the present economy. As a business in a struggling economy there are pressures to export and outsource functions your business used to consider part of your core competency, and so how do you adapt your operations strategy to combat the outsourcing of your operation? The simple answer is through a review of your core competencies and an addition of opportunity exploitation to supplement your bottom line. 

The act of off-shoring a function is to derive either a strategic advantage or a cost advantage in a given activity. Given the struggling nature of Ireland’s currency Ireland is in a prime spot to utilize their ailing currency to become a low cost provider of services and goods. Every job in the organization needs to be evaluated in terms of its “outsourceability” and the leaned out to remove the waste in the process. Simple data entry jobs are typically those first outsourced as well as call center positions that pose no real physical requirement to be in the country. However an organization can look outside of their core competencies and offer the opportunities that their business creates to a wider market base and turn those tasks into profit centers. Through value stream mapping and sound lean concepts it is possible to derive a profit for the service at a price lower than some off shore companies.  In their book Rework the authors hit it right on the head that “You cannot make something without making something else”. Operations in a country must look at the off-shoots of their process to leverage it into a profit. 

The common response to this is “we are not in the call center business” or “we are not in the daycare business” .However in the new future with more mobile options for both your workforce and your clients these sorts of opportunities may be the new competitive advantage as the price for your core competencies dips as a result of increased competition from lower priced areas. Some of the areas that a business should be looking toward includes derivative information that is the spin-off of their data mining process, companies will gladly pay for the data you spin off anyway and do not use as part of your process. More tangible goods may be the plastic shavings from your turning process that can be used by an injection molder somewhere, or the tooling process that you created to meet your own needs. Leverage these non-core competencies and you will find the push to outsource will not result in either a cost nor a competitive advantage, and this will keep your domestic operations humming. 

Well, Someone Has To Do It

One of the common problems our Mentors report with SME business owners is an attempt to do everything themselves.

The small-to-medium business model, with its flat hierarchy and limited resources tends to force owners to take on tasks outside of their range of experience and skills. When confronted with an activity that the owner doesn't like, doesn’t have the proficiency for, and doesn’t have the internal resource for, the owner will still tackle it. He or she will typically defend this investment of time by saying “Well, someone has to do it.”

My case in point today is a small manufacturing operation. The owner is a 50-year old man with a background in woodworking, who found (quite by accident) that the furniture industry was underserved in a particular area and stepped in to fill the niche with quality products.  Although his products were outstanding, he consistently struggled with the online marketing for his business, and ended up building his own e-commerce website. 

Not to put to fine a point on it – the website was horrible. The only people who bought from it were those who were already avid fans of his business, and who were willing to muddle through pages of poor design to get their products. As an e-commerce platform for new purchasers and as a representation of the high-quality, high-cache products he was selling, the site failed terribly.  More importantly, each time I talked to the owner, he spent a great deal of time expressing frustration over how much energy and effort the website was taking.

His problem was solved with a simple question: “What else could you have been doing with that time?” When brought up, he thought of a hundred things that he could have been doing – glad-handing the large clients, developing a better product mix for the upcoming season, attending events that would raise the profile of the business in the industry, or creating a sales strategy for the busy season.

The concept of Opportunity Cost cannot be stressed enough in small business. In a flat hierarchical environment, the owner’s time must be spent doing only those things that he or she can do. Although this small business owner was leery to pay for outside help when he could do the job himself (however poorly), he had to recognize that aside from the tangible costs of paying someone to do his website, there was an opportunity cost for things he couldn’t get done while he was worrying about the website. 

With this in mind, the furniture e-store hired out a complete redesign at a reasonable cost, and the small business owner generated sufficient business to cover the investment by focusing on the tasks that only he could do.

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