A Great, Inexpensive Way to Recognize your Employees

I am fortunate enough to work with a large group of high-performers every day. Without the support of my team, coworkers, and vendors, our supply chain and operations would end quicker than a diet in a fudge shop. I thank people around me often, but sometimes I feel they deserve even more recognition than a quick “thank you.” However, with budgets being so tight, it’s difficult to give them anything of extrinsic worth. As I have tried to be creative in my methods of recognizing people in a way that will be meaningful to them, I have found a superb way of showing appreciation that only costs a dollar. Because of the significant intrinsic value in this method, it has quickly become one of my favorite HR tools.

Recognition for a Dollar

Fire Truck Award

Some time ago, a team I was on had worked tirelessly to successfully launch a new product line with a key customer. The day after the launch was complete, the brand manager, who was armed with a secret box, gathered the entire company together. From his box, he pulled out a fire truck that he had purchased at a dollar store and called up a team member to give it to her. He talked for a minute to all gathered about how this team member had stayed very late for several weeks to put out fires. He thanked her publically, and she kept the fire truck to proudly display on her desk.

Continuing with his secret box, the brand manager next pulled out a microphone. This was for the team member who was always voicing concern and helping come up with solutions. The manager also presented a hairbrush to the designer who had helped to make the product beautiful. Next was a game of jacks to the employee who was a “jack of all trades” and kept up with broad details.

The meeting was a hit; everyone felt appreciated and had a good laugh. Following this tradition, I’ve seen quite a variety of unique dollar store gifts of appreciation:

  • A thermometer – keeping cool under stressful situations
  • Bouncy balls – Always staying on the ball and steadily working on long tasks
  • An inflatable sword – “The Sword of Accuracy” for making sure orders are complete and correct when they ship
  • A bath toy boat – Helping keep orders shipping on time – and doing great at managing logistics
  • The Hulk Action Figure – Tirelessly wrapping pallet after pallet and doing much of the heavy lifting
  • Glow sticks – Keeping the team upbeat and making stressful work more fun
  • Magic wand – Ability to magically solve problems
  • Giant Dollar-sign Glasses – Catching small detail problems to help save money

Almost anything can creatively be turned into an award; you might even be able to just collect a few unneeded items from your home.

This method of recognition is effective because it’s memorable and fun for everyone involved, not just the people being recognized. The entertaining prizes keep everyone engaged (imagine how much better the Academy Awards acceptance speeches would be if the awards were something fun like oversized novelty hats the recipient had to wear). After the fun recognition meeting, each team member wants to see the others’ toys and hear again the special importance attached to them. Making them funny, but also putting serious thought and appreciation behind the awards will give them meaning. Recipients will be sure to tell their family about the fun award, and they’ll likely hold onto it for some time.

The best way to carry out this method of recognition is to go to a dollar store and wander the toy section until creativity strikes you. When examining a specific product, think “what could this represent?” or “what funny play on words could I make with this?” Have fun and stretch the meaning as far as you need to – the words you’ll say mean much more than the object you’ll give.

Be sure to make a detailed list of who the award is for, the meaning behind the award, and several specific examples of what that individual has been doing for the company. Without a list, I usually stumble and forget the details behind the award during the presentation. It’s embarrassing to be holding a Frisbee and completely forget the meaning behind it.

A Couple Disclaimers

Appreciation at work is extremely important to employee retention and motivation. However, this should not be a substitute for fair wages and increases when appropriate. Additionally, do not overuse this method – using it every week would quickly diminish its novelty and usefulness.

Other Effective Methods

Here’s a Dollar

The school my wife works at uses dollars in a different way to recognize outstanding teachers and staff. At each faculty meeting, the principal has five $1 bills at the front of the room. At a specific point in the meeting, anyone in the meeting can go up, take a dollar, and then give it to someone and explain to everyone what that person did to deserve recognition. This is a great way to encourage recognition that has the additional benefit of having team members recognize each other instead of relying only on recognition from supervisors (who may not see all of the great things that an employee is doing.)

Call for Appreciation

Another effective method of recognition is something I saw when visiting O.C. Tanner. Every morning, teams meet for a morning stand-up huddle. After reviewing key metrics and the day’s priorities, the meeting leader calls for appreciation. Anyone who has noticed someone doing something good steps to the center and compliments the person. If the person isn’t there, his or her manager makes note, and both the person offering the compliment and the manager make sure to recognize the person that day.

Smokey the Bear

Smokey Bear Vintage Tin Sign from Amazon

Emergencies and fires plague a lot of companies. Employees who prevent fires are often unnoticed despite the great good they play in the company. To encourage fire prevention, I know a company that bought Smokey the Bear memorabilia as awards. These items, such as a vintage “Only You” sign or a Smokey Bear Coin, became coveted trophies that helped recognize and encourage fire prevention. Suddenly the heroes of the company aren’t just those who solve problems, but those who avoid them before they break out.

Final Thoughts

No matter what you do, take some time to recognize your team. Systems and processes are great, but it’s the people that make companies work. When the work day is over, 90% of your company’s assets walk out the door. Appreciation, whether with the fun dollar-store method or some other way, goes far in keeping your team happy and the supply chain running.

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    Your Spreadsheet is Lying to You

    I love Excel spreadsheets. There’s nothing more satisfying than turning a blank Excel grid into a fountain of data and conclusions. Invite over pivot tables, external data, and macros, and suddenly you have an entire business analysis party. You can confidently make big dollar decisions from small and simple cells – or so we think.

    Excel Lying

    Knowing my dependence and appreciation of spreadsheets, a good friend sent me a very interesting Wall Street Journal article, 88% of Spreadsheets Have Errors by Jeremy Olshan. In the article, Olshan exposes how almost all spreadsheets have at least one error in them, and large spreadsheets are usually filled with mistakes. We often are so rushed to get the calculated conclusion to other people that we don’t take time to check our formulas and have someone else proofread our work. Miscalculations and mistrust of analysis can often be the result. The article mentions major economic research that drew incorrect conclusions based on flawed spreadsheet formulas. Likewise, I’d like to share a story of how incorrect cells can wreak havoc on supply chains.

    Barcode Blunder

    I still shudder to think that a simple, one-sheet spreadsheet completely ruined two weeks of my life.

    My company uses a barcode printing program that pulls its information from a simple spreadsheet. The spreadsheet allows users to easily enter the item number they need, and the close-by thermal printer quickly spits out the barcode stickers. I had set up the spreadsheet to pull all the necessary information, including the 12-digit barcode and description, from external sources when the item number was typed in. The formulas worked great, and the spreadsheet seemed perfectly self-explanatory. Or so I thought.

    Because the interface was so easy to use, more and more employees began to use it to print barcodes. This was great for me because I was not called out seven times a day to print the stickers. However, the lack of standardized training and safeguards eventually created a problem. Seeing the UPC column, someone replaced my formula that calculated the UPC with a static 12-digit UPC number for the item they needed. Having been saved with the incorrect number, the spreadsheet now printed the same, incorrect UPC barcode for every item. However, because the description was correct, no one caught the error. Worst of all, that week we had a big project that required a large number of labels.

    One of our customers increased their orders significantly for an item that we had to label individually. This amounted to over 50,000 incorrect barcodes stickers that we put on, and then shipped without knowing the error. They went out the door on time, and the problem wasn’t fully realized until the product was already set in thousands of retail locations.

    Was the Spreadsheet to Blame?

    So who or what can we really blame for this mistake? After lots of pondering, I couldn’t blame anyone but myself – the creator of the spreadsheet. I don’t know who changed the cell, but it really wasn’t that person’s fault. Whenever I create a process, program, or spreadsheet for others, I need to make sure it’s error-proof. To fix it, I immediately locked down all the cells and rewrote the spreadsheet to be much harder to incorrectly edit (some simple poka-yoke, or in English, error-proofing). Just as important, we added a barcode-check step in which we scan the barcode and get a second pair of eyes to approve it. So, when the malevolent spreadsheet decides to strike again, we’ll be able to catch it.

    While this may be a story more on the need for better processes, it also illustrates the devastating power one spreadsheet cell can conjure.

    In the end, the retailer was able to change their computer system to accept the incorrect barcode, so the effect on end consumers was very minimal. The real pains were internal as we identified our process problems and worked to correct them. Of course, I lost some sleep and worked under heavy stress for a couple weeks, but as a result, I learned some important lessons – not the least of which concerns spreadsheets.

    Five Tips toward Error-free Spreadsheets

    Even if the world is plagued by lying spreadsheets, we can still personally become sources of accurate and correct data analyses. Here are five tips toward more accurate spreadsheets.

    1. Get Someone to Proof Your Work and Make You Explain Your Formulas

    If you do nothing else, please do this: Ask someone to look through your spreadsheet and test all your assumptions and formula logic. Have them examine key calculations closely and confirm everything is calculating correctly. Offer to do the same for your friend’s spreadsheets in return.

    2. Trace Cell Relationships

    excel trace function

    Excel’s trace functions, found under the formula tab in Excel 2007 and 2010, are excellent ways to make sure all the cells you think are included in a calculation actually are. Trace precedents will point arrows to all the cells that feed into the cell you’ve selected. Trace dependents show all the cells depending on the selected cell. These help you catch problems of cells sneaking in or out of formulas – as well as seeing what might happen to other cells when you change the current cell’s value. Plus you feel pretty smart when there are hundreds of arrows all over your screen, “Wow, I can make some intense calculations.” Note that this step would probably have helped me catch the error in the story above.

    3. Verify Links

    Update Links

    External data, especially from other spreadsheets, can be very tricky. Excel isn’t the best database system in the world, so links sometimes break or don’t update. To avoid problems, verify and update links through the edit links button on the data tab. This tool let’s you ensure links are active and correct. I’ve had many links break for no apparent reason, so be vigilant on checking this frequently.

    4. Address background error checks

    Background Error

    Those little triangles in the top left corner cells are signaling that Excel thinks something might be wrong. Address them all, since often they are true problems. Only ignore the error if you’re sure it’s not an error, and the triangle will disappear.

    5. Force Excel to Calculate

    There are several reasons Excel stops calculating formulas. Usually it’s because calculations are turned off, but sometimes big files have quirks that hamper calculation – especially when VBA is involved. To recalculate all formulas and update all links, press Ctrl + Alt + Shift + F9. If you have external data, you’ll want to use the Refresh All command. If you have pivot tables that pull from External Data, you’ll want to refresh the pivot tables after you Refresh All (or Refresh All twice). Pressing Refresh All twice, then pressing Ctrl + Alt + Shift + F9 will refresh and calculate everything possible.

    When You Need to be 100% Accurate, Rebuild from Scratch

    Although these tips will help you catch many errors, there are still chances of problems. Several third-party vendors offer error-checking software. I’ve never tried them, but I do have a pretty strong technique to ensure high accuracy. For very important spreadsheets and decisions, I often recreate the entire project from a blank workbook to confirm everything is correct. I don’t copy and paste, but instead retype the formulas to make sure everything matches. Quite time intensive indeed, but duplicating my work usually takes a fraction of what it usually takes to create it. In fact a two-week spreadsheet took only an hour to completely rebuild from scratch because I knew exactly what to do. Having rebuilt it, and with everything matching perfectly, I feel confident that my spreadsheet is accidental-error free. Of course, whether my human assumptions are correct is an entirely other issue.

    So the next time you find yourself in possession of a breakthrough calculation in Excel, I hope you’ll be a bit more leery that your spreadsheet is likely lying to you in some part. Encourage honest spreadsheets by error checking and proofreading so we can all avoid painful spreadsheet problems.

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      How to Win Friends and Influence People in Your Supply Chain

       

      How ti Win Friends and Influence People in the Supply Chain

      Even though supply chains are becoming more automated, people still play a critical role in successful interactions and product flow. This is especially true for most small businesses. Relationships and conversations matter much more to small businesses because they don’t have the power of Walmart or Apple to rely on novel-length contracts and impersonal automation. Instead, phone calls, personal visits, special favors, and constant cooperation are what keep small companies alive and their products flowing. So it makes sense that the ability to win friends and influence people in your supply chain is a powerful skill that is needed to help your company survive and flourish.

      I recently finished listening to the business classic, How to Win Friends and Influence People (HTWF&IP), by Dale Carnegie. Although originally published over 75 years ago, it’s still a consistent bestseller because it’s simply a great book. The lessons are timeless and apply directly to everyday life in along the supply chain. I’d like to share a few simple examples of how I’ve seen the book’s suggestions directly help me solve problems with vendors, customers, and fellow team members.

      Always Make the Other Person Feel Important

      “There is one all-important law of human conduct. If we obey that law, we shall almost never get into trouble. In fact, that law, if obeyed, will bring us countless friends and constant happiness. But the very instant we break the law, we shall get into endless trouble. The law is this: Always make the other person feel important.”

      “Make the other person feel important – and do it sincerely.”

      ― Dale Carnegie, HTWF&IP

      The strongest takeaway I gained from the book is that making others feel important can help solve most conflicts. The key, however, is to do so in a sincere way. Never use flattery or give undeserved phrase. However, by recognizing the important roles that others play – and seeing problems from their perspective, you can give them the due respect and honor that you would like to be given if you were in their place. Often problems vanish as soon as the other person feels acknowledged and respected.

      I’ll first share an embarrassing example I’ve realized about myself. My company often gets last-minute rush orders that fall outside our normal fulfillment time. We have a standard lead time, but sometimes to win the sale, our salespeople must promise delivery in a much shorter period than our standard. When those orders are thrown at me, and I’m ordered to make it happen, I find myself reluctant to do so. However, when someone approaches me kindly, acknowledges how busy my team is, and asks me to please consider making an exception this one time, my attitude is completely different. I feel important and thus do everything I can to make sure the order succeeds. Of course, I recognize that I need to work on helping all orders succeed equally, but you can see how powerful an extra 30 seconds of conversation can be.

      How to Win Friends and Influence People

      Utilizing the same principal, I recently helped schedule a delivery appointment with a key customer even though we thought it couldn’t be done. Our warehouse supervisor had called for an appointment at the end of the month, and because the customer was fully booked, the customer said we couldn’t deliver until several days later. Our CEO wanted us very much to deliver within the month, so I called back. I talked with the same receiving clerk for a few minutes. I acknowledged how busy he was and listened for a minute about everything he had going on. I praised him that he’d be willing to handle that much on a Friday. After just a minute of getting to know him a little more, I explained that our order was very small, just a few cases, and he would be doing us a great favor if we could sneak it in between his many other important shipments. He said it wouldn’t be a problem – and we delivered that afternoon. Not only did the order get delivered on time, but I now have a friend at our customer’s warehouse that I look forward to talking with again.

      Make others feel important – and do so sincerely.

      Continuous Improvement through Continuous Praise

      “Let us praise even the slightest improvement. That inspires the other person to keep on improving.”

      ― Dale Carnegie, HTWF&IP

      Enabling others to improve is one of the most rewarding and effective methods of improving your company and supply chain. Through improving and encouraging the job skills, creativity, and problem solving abilities of others, your entire network will benefit from more engaged players and improved processes. In fact, a key tenant of the Toyota Production System is to encourage improvement through the creativity of every one of its employees and supply chain members. Imagine if Toyota managers were dictatorial, constantly shouting out commands and berating employees for mistakes. It’s not a stretch to predict that Toyota would be out of business if that’s how they managed their people.

      Praise, in contrast, has an almost magical effect in motivating others to improve. Based on this principal, I’ve watch my company grow one of our key suppliers through targeted praise – and withholding the occasional frustrations.

      When we first started producing one of our new products, we found a small firm of just a few people that was eager to work with us. Although eager, they often had quality control problems, delays, and incongruent processes that come from being a young company. I became frustrated many times, and recommended dropping them as a supplier – even though that meant they would likely go out of business.

      Despite my recommendation, my wise manager counseled that we keep them on as a continued ally. My manager was careful to encourage them to improve:  he identified and focused on what they did right. When problems surfaced, we took a shared-problem approach and tried to solve the issues in a way that we and the supplier would bear responsibility together for improvement. We rewarded their progress with compliments and increased orders.

      Because of the years of patience and encouragement, this supplier is now our miracle worker. We have other, more advanced suppliers. However, when we’re in a tight spot, no one can pull off an emergency order with next to no lead time like that small supplier we’ve grown. Because of this supplier’s expertise at short-notice orders, we’ve been able to catch many sales opportunities that we would have otherwise needed to pass up – or pay much more in expedited freight. I’ve witness how patience and praise can help a supplier grow to a point that boosts your bottom line when no one else can.

      Avoid Arguments and Let Others Save Face

      “If you argue and rankle and contradict, you may achieve a victory sometimes; but it will be an empty victory because you will never get your opponent’s good will.”

      “Letting one save face! How important, how vitally important that is! And how few of us ever stop to think of it! We ride roughshod over the feelings of others, getting our own way, finding fault, issuing threats, criticizing a child or an employee in front of others, without even considering the hurt to the other person’s pride. Whereas a few minutes’ thought, a considerate word or two, a genuine understanding of the other person’s attitude, would go so far toward alleviating the sting!”

      ― Dale Carnegie, HTWF&IP

      In the course of your interactions with customer and vendors, I guarantee that points of disagreement and contention will arise. Huge quality problems, incorrect freight counts, painful cycle counts, overdue orders, key stock outs, mountains of obsolete inventory, and…well, I’m sure you could add another 20 problems to the list. Indeed, problems are so common in the supply chain that I’ve heard supply chain management called problem management or fire management. But how do we fight fires while still thinking long-term? Indeed, supply chain success comes not only from solving the temporary problems, but creating long-term cooperation and synergy through strong relationships. Thus, we find ourselves in a precarious balance between the problems of today – “who’s responsible for fixing and paying for this?” – and long-term partnerships to improve the entire supply chain – “how can we improve information and product flow along the chain?”

      Better defined, the risk we face is allowing the problem of the day to slow and destroy the progress made on long-term relationships. Even if someone is particularly difficult to work with, venting your frustrations and giving that person a piece of your mind could easily set back months or years of investment. Even if you’re completely right, avoiding argument – or letting your opponent gracefully retreat – may be the smartest move to make.

      Certainly when money is involved, the process takes on higher stakes. In the interest of our companies, it certainly befits your and I to recover money that is rightfully ours. However, when arguments or disagreements become personal, bitter, and unrelated to the actual problem – these are fights to avoid.

      When dealing with some of our Asian suppliers, this concept becomes especially important. Asian cultures treat conflict differently than other cultures. Saving face is much more important there than in the US or Europe – although we often fail to realize that it’s still quite important in any culture. When problems arise, if we are able to deflect the blame away from any specific person and instead focus on solutions, our suppliers are much more willing to work with us on solving the problem. For example, whenever I send an email to a supplier that dictates, “This was your fault. You need to either do this or pay a significant penalty,” nothing good ever comes from it. However, when I am able to approach the problem as the following, the problem is often rectified: “We noticed this problem. This is not good because our end consumers are not happy when this happens. What can we do to solve this problem?” Working together to solve a problem is always more productive and rewarding than pushing a punishment.

      Final Thoughts

      How to Win Friends and Influence people is a great reminder of how we should treat others. It brings together a lot of applicable advice on how to interact with people, and therefore becomes an excellent real-world resource that teaches just what the title professes.

      I enjoy spreadsheets, databases, and technology, but relationships with people are more important than any automated email alert. Carnegie cites a study that explains how “even in such technical lines as engineering, about 15 percent of one’s financial success is due to one’s technical knowledge and about 85 percent is due to skill in human [interactions] and the ability to lead people.” I see it as no stretch to say that at least 85% of the success of your business in the supply chain is your ability to interact positively with others.

      If you’ve already read Dale Carnegie’s book and would like another great read on improving human relations, then I recommend Leadership and Self-deception.

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        Better Supply Chain Decisions through Data Analysis

        “Should we cancel the purchase order? We need to know today – and we can’t be wrong on this.” Only two-thirds of stores had reported any sales data from a newly launched product, and my team needed to know whether or not to invest tens of thousands of dollars in additional replenishment inventory. We already had a very large number on order, and based on pre-sales forecasts, we needed nearly double what we had coming. But with just a few data points, was it possible to tell whether we needed the stock or not? It all came down to the data: Could it be trusted? Were my assumptions correct? Was there enough to act on?

        Soon after finishing business school and starting my career, I was quickly surprised by the contrast between the discussions that took place in the classroom and in conference rooms at the office. In academic case studies, my classes would look over graphs and charts to find important business lessons that the professor was helping us discover. In the real-world however, emotions, hopes, politics, and persuasion often make decisions much less clear than a business school case study. The small business I work with often relies on its supply chain team to make many decisions that require extensive data analysis. With moderate experience with excel and databases, my team has been able to slowly help our company make better decisions by taking out the myth of emotion and replacing it with the confidence of data.

        Data-driven Analysis

        Forecasting, inventory, purchasing, logistics, and process improvement are often done by gut-feeling in very small companies. When you don’t have the systems or people to gather and process the information, making your best guess is often all you can do. When operations are small, this works most of the time because you are able to get a feel for most parts of the business since you’re involved with most parts. But as the company grows, staying connected with each part of the supply chain becomes increasingly difficult. If you haven’t already, this is when you must switch from trusting your feeling to trusting your numbers.

        There’s an excellent quote that I like:

        “In God we trust. All others bring data.”

        -W. Edwards Diming [Source]

        It highlights that no matter how much we trust our intuition about a decision, numbers are often what really matter.

        Which Data to Use?

        One of the biggest problems with data in modern systems is the sheer size of the information you collect. If academic case studies were 200 pages instead of 20, schools might focus more on training students how to sift through the noise to find the important data. However, until then, experience and past trends are the best guides for making decisions.

        With so many numbers in your system’s database, each department or side of a decision can often build a data-backed case for why their solution is the best. It then becomes important for the head decision maker to be able to judge which information is most relevant and accurate. He or she should start by asking the following questions:

        • Where does this information come from?
        • How was the data collected?
        • What are the assumptions being made?
        • Why do the two (or three or more) data points show different trends?
        • How could these conflicting results actually be pointing to the same conclusion?
        • What numbers can we all agree on?

        By agreeing on the same assumptions and the pertinent data sets, you can better reach agreement on how to move forward with the information you have.

        When the Numbers Lie

        Sometimes, the numbers tell a different story from reality. Even if all analysis points to buying more of product,  only you can tell that the product will soon be discontinued, and that you don’t need more stock. Often data analysis isn’t so much about manipulating the pivot table, but adding the pertinent information that the system doesn’t cover. Adding everything you know that the system doesn’t, and then looking at the data all together often helps you make the wisest decision.

        Highest and Lowest Case Scenario

        “It’s only about two weeks of data, but it’s enough to make some decisions,” I said.

        “I’m just not sure if we can trust it yet. There’s so much we don’t know,” a sales analyst replied. There were still many questions that we couldn’t answer. How many stores had yet to receive the product? Could the product still be in the back room? What if employees had bought the product instead of customers? I needed some way to make the 10 days of sales data point to something – and I needed enough confidence in the numbers that everyone could trust them.

        I looked at the data again, and I wrote out what assumptions I could make. To reach my averages, I assumed every possible reason sales could be artificially low was actually taking place. Based on these high assumptions, I determined that average sales per store would likely be less than 3 per week. There were enough stores that had initial sales data that I could confidently say sales would very likely be between a high of 3 and a low of 1 per week. This was significantly lower than the 10 per week forecast for which we were about to place a purchase order.

        “The data is convincing – and even if the high boundary number doubled to six per week, we’d still have enough without this order,” the brand manager replied. “Ten per week just isn’t a realistic expectation. Let’s cancel the order.”

        By giving a confident range of average sales, I was able to help my team make the right decision and avoid large overstocks of inventory – something we have continually struggled with throughout the company’s history. Sometimes there isn’t quite enough data to make a definitive argument. In cases where you have even some data, using high and low assumptions can often give you enough confidence to move toward the right decision.

        We’re not robots – and we shouldn’t focus solely on numbers. However, by incorporating more data into our decisions, we can often find better and more predictable results. The key is to know what data is useful, opposed to noise, and how to use that data correctly. Looking at the same, accurate data, and deciding on high and low assumptions are strategies that have helped move our company in the right direction.

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          Three Silver Bullets to Solve (and Raise Red Flags on) Nearly Every Supply Chain Fire

          This past Wednesday, I was presented with a problem. “Alex, your team needs to unpackage, relabel, and repackaged 10,000 of these items by noon Friday.” The product needed a warning label that we just barely learned was required by law. Running on our smallest possible staff, my team suddenly had a mountainous challenge before us that years ago would have kept me up at night worrying. However, I slept just fine because I knew we could handle the challenge with one of my three secret weapons. In fact, I’ve learned that I can solve nearly any supply chain fire with one or more of three things:

          1. Air Freight
          2. Temporary Workers
          3. A Rotary Drill

          I initially put together this list as a joke. Executives would approach me with a problem, to which I would reply, “it’s nothing air freight, temps, or a rotary drill can’t solve,” and suddenly the stress of the problem decreased. I still don’t completely rely on these three silver bullets as the solution to any problem. However, with these three tools, my team has conquered surprisingly large amounts of fires that our small supply chain faces.

          Perhaps more importantly than taking the stress out of emergencies, these three silver bullets also serve as a signal that our processes have room for improvement. Throwing money at a fire through expedited freight and increased payroll is a sign of deeper problems. Nevertheless, when 10,000 items need to relabeled in the next 36 hours, I need to solve the immediate blaze with whatever I can before backing up to prevent future sparks.

          Silver Bullet One – Air or Expedited Freight

          Silver Bullet One - Air Freight

          Air freight is a needed miracle in modern supply chains. When problems arise, switching to faster shipping can save the day by cutting lead times from distant suppliers significantly. Those precious extra days can help capture last minute sales opportunities and help avoid expensive stock outs. Recently my company learned that one of our products was scheduled to ship to twice as many retail stores than originally planned. We had purchased inventory according to the original forecast, which would be insufficient to meet the new demand. However, by air freighting in product that was just finishing production in China, we were able to fulfill the order and capture the extra revenue. The higher shipping costs took some margin, but the ability to prevent three or four weeks of stock outs was well worth the cost. Realizing that I have an expedited restocking option has helped me reduce my safety stock and keep my company’s inventory investments smaller.

          Another problem I often face is large customers needing product before we have it. We’ll tell customers that the launch date for a product is May 15, but then the customer will send a purchase order for an April 25 delivery. We often push back, but sometimes the customer will simply cancel the order if we cannot meet the date. Enter air freight again to save the day.

          Although air freight can help your company get through a variety of tight spots, it’s not a good habit to constantly use it. Each time we’re forced to use air freight, it’s an expensive red flag telling us that we need to improve our systems, vendor performance, or customer relations. Nevertheless, expedited freight is an excellent tool to combat supply chain uncertainty.

          Silver Bullet Two – Temporary Workers

          Temporary Workers

          When emergencies blaze out of control, we instinctively call in reinforcements. Dealing in consumer products, I’ve had countless experiences of relabeling, repackaging, and reworking product days or hours before it needs to ship. Often the rework could have been easily avoided months ago from simple communication or error proofing. However, problems slip through insufficient safety nets, and suddenly I’m flying to an offsite warehouse to oversee emergency rework for an urgent order.

          Some time back, we had a large promotion ready to ship to one of our top customers. It was in our offsite warehouse prepared to ship the next day. As I reviewed the pictures of the product to confirm everything was good to go, I noticed some unfamiliar labels on the carton. I inquired for more detail and found that although the outside carton labels were correct, the inside product had incorrect barcodes. Over 70,000 products needed new barcode stickers put on them – and they still needed to ship within the next day or two. I jumped on the next flight and assembled a team of 18 temporary workers to help. We quickly created a system to move through the pallets and relabel the products. It was August, and the heat made me sweat almost as much as our looming deadline. However, thanks to my 18 new friends and my assistant who made sure I ate and took breaks, we were able to complete the project in less than 24 hours and ship the entire order on time.

          Using temporary workers for unexpected fires is a clear red flag that upstream processes need help. However, as stated at the beginning of this article, knowing that calling in a few extra people can easily solve the problem takes much of the stress out of supply chain firefighting. Using temporary workers consistently may also be a sign that you may need more permanent additions to your staff.

          Silver Bullet Three – A Rotary Drill

          Rotary Drill

          Originally not part of the silver bullet arsenal, a rotary drill in the right hands can solve major problems or inefficiencies in just minutes. It’s my weapon of choice with hands-on problem solving because of its versatility. With a rotary drill (and other tools), my team has built holders, pegs, product paths, and jigs that have often quadrupled production speed. Rather than accepting a process as just slow, a few minutes or hours of building additional tools, holders, or aids can skyrocket efficiency.

          For example, as we manufactured one of our products, we needed somewhere to put the small raw materials before they were processed. Laying them next to the worker often resulted in a slight breeze blowing the very light material off the table. Additionally, the worker spent more time aligning the pieces on the machine than actually using the machine. Enter the rotary tool.

          By creating a board with nails to put each piece on, we could drastically reduce the time it took to align the raw material on the machine. Putting it on a nail would allow it to stay aligned the entire time. The problem was that the nails were rough and would often snag the materials to create defects. Rather than complain and brainstorm different solutions, we just grabbed the rotary tool and smoothed down the nails. Suddenly, the entire operation was running smoothly, and much quicker than before.. Building small, creative tools – even if they’re not perfect at first – can save loads of dollars and hours.

          Think While You Reload

          As you remove the spent cartridges from your silver bullet six shooter, think about what could have prevented you from pulling the trigger. Every good Western movie needs a shootout, but the best supply chain cowboys I know avoid pulling the trigger altogether. Each time you resort to air freight or temporary workers think about how you could have solved the problem further upstream. The rotary tool may not raise the same number of red flags since it often helps create better processes, but sometimes I also use it as a last-resort solution that could have been solved earlier on.

          A good way to improve is to hold a quick meeting each time you fire a silver bullet solutions. Five minutes addressing three questions could prevent future shots:

          1. Why were we forced to us a silver bullet solution to solve this fire?
          2. What could we have done to prevent this fire?
          3. What will we do differently next time?

          A quick meeting with answers to these questions, combined with action items, will improve your processes and help you build up fire prevention measures.

          What other silver bullet solutions do you have in your arsenal? Please share yours in a comment below, and don’t forget to subscribe to future articles.

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