Tag: margin
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When the tide goes out, it exposes products that were under water
The number of companies with complexity reduction initiatives has skyrocketed. Unlike five years ago, these are serious initiatives with management sponsorship and timelines.
A good friend of mine, who is a salesperson at a Caterpillar dealership, told me that when times are good he can sell any machine. When the times are bad, the bad stuff just sits around exposed.
Companies have proliferated their product offerings – there are almost infinite variations of everything that they offer. The rationale is that they will make one more sale because of that variation. But as product variations grow, the cost structure grows very fast as well, and the probability of finding that one customer who wants the new variation is quite slim. This results in excess inventory across the supply chain. And when the economic tide goes out, it exposes the cost of those product variations.
The companies with complexity reduction initiatives recognize that during good times and bad, managing product variants makes good business sense. Companies are now starting to implement metrics to measure product complexity because we all know that what gets measured gets managed! Product complexity metrics quickly expose underwater products.
The comment by my friend at Caterpillar reminded me of a trip I took to the Bay of Fundy. It is amazing how much is exposed when the tide really goes out, just like in this economy. The good news is that when the tide turns, the bad product lines it once covered will be significantly fewer, resulting in healthier and more competitive companies.
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8 more definitions you need to know for product complexity analysis
1. Kit
A kit is a collection of parts that are used together for some purpose — for example, all the parts needed to implement air conditioning on a particular model of a car. A kit is assigned its own part number.
2. BOM
BOM stands for bill of materials. When a customer makes a selection of choices chooses a configuration (i.e., makes a complete set of option choices), the manufacturer translates the order into a collection of parts that are needed to assemble it. The BOM is expressed in terms of part numbers. These part numbers may refer to whole kits, composite parts or specific atomic parts. A complete vehicle, or washing machine, will contain many parts that the customer has not chosen. But these parts appear in every instance, or else they are implied by the combination of choices that the customer made.
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Product management to fit?
I often hear clients say, “We’ve been told by management that we should only have a standard and premium model.” Then product teams are tasked to fit the line to that limitation, while no product analysis was done to support the decision.
While reduction in configurations is important, how it is achieved is just as important. Using a quantitative approach earlier in this decision-making cycle can help the management team make an informed decision. Maybe a reduction to two models is just too aggressive; adding one additional model might be the difference in having proper market coverage. Examination of customer buying trends and patterns should be the first indicator for product direction. Determining product strategy based on market needs as opposed to retrofitting the product to an idea could lead to more effective product lines for both the manufacturer and consumer.
Why product complexity matters
I was telling some friends at a brunch about what I do, and how variety drives cost in manufacturing. “But all the manufacturing has moved to China,” commented one person. I’ve heard this comment over and over.
A picture is worth a thousand words — and here’s one that fits the bill.
- Commoditization of labor in manufacturing
- Higher output per worker
- The percentage of cost in goods is much higher
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