25 Questions

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25 Questions

1. A piece of lumber travels _____ feet between the time it arrives in the yard and when it goes out the gate as part of a finished component.

2. How do you measure the quality of the components you build?

3. On average, our prices are ____ % (above/below) the competition.

4. This Fall, the work we have had has kept us working at about ____ % of our maximum capacity.

5. We stock ____ sizes of plates and the plate we use the least is the _____ plate.

6. The one thing I would change about our plant layout is _________________________.

7. In the past 24 months I have visited ____ other component manufacturers.

8. The reason most of my customers would say they buy from me is ______________________________.

9. If our order backlog doubled next month, we (would/would not) be able to handle the work.

10. Plates represent about ____ % of the selling price of the trusses I make.

11. The most knowledgeable person I know in our industry is ______________________.

12. Are your sales reps positively or negatively affecting your sales?

13. Our average job site is ____ miles from the plant.

14. We have to deliver additional materials (to replace broken or missing ones) on ____ % of our jobs.

15. The one piece of equipment that I think would help us the most is __________________ because ___________________________ .

16. Designer productivity is measured by ____________________________ . Designer quality is measured by ______________________ .

17. Who arrives first in the morning more often than anyone else?

18. We have quoted ___________________________ (name whoever is #1 in this category) _______ times and never received one order.

19. The most satisfying thing I have accomplished at this company is _______________________ .

20. How do you reward yourself and what do you reward yourself for?

21. It takes an about ____ minutes to set up a 40’ common truss on my main table.

22. For a business, what are the three most important ‘keys to success?’

23. The biggest obstacle I ever overcame in this industry was then I _____________________ .

24. If stocked half as many skews of lumber it would cost me $ ______ (more/less) per month to operate.

25. Over the Winter we are going to tackle that _________________ problem.

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The World Where ‘Eck You A’ Reigns Supreme

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The World Where ‘Eck You A’ Reigns Supreme

Scholars tell us that coins began to be used between 400 and 600 B.C. They were a big hit. Bartering is great, but it has its limits. Coins soon became a widely accepted, universal unit of exchange. Now imagine a world where all component manufacturers have a unit of exchange that is just as valuable as coins are. Because this unit of exchange is completely accepted by everyone, manufacturers can easily compare the production efficiency with each other. Everyone estimates their jobs using the same method. Getting a quote from another manufacturer to build trusses for you is a snap, because you both measure jobs in exactly same way. Oh, and by the way, this is a real place. It is called, ‘Australia.’

Down Under

It’s really true. In Australia, virtually all manufacturers have “bought in” to the concept of converting all forms of work into EquA’s, or “equivalent finks.” Getting deeply into EquA’s can get complicated, but the basic idea is simple. Convert all work into the single unit (our “coin.”) This is done by arbitrarily declaring that “a standard fink truss with one splice takes 1 EquA to build.” The next step is to come up with a method to determine how many EquA’s it takes to set up (as opposed to build) that truss. From there, we have to come up with an easy way to determine the EquA for all truss types. In Australia, this is mostly done through the number of joints, but, as I said, it can get a little complicated. Attached is a PDF describing the method in some detail, if you are interested. My purpose here is not to explain the method, but rather to describe the benefits that the Australians enjoy because they all use the same method to measure work.

The Point

I had heard about this method of estimating before my trip to Australia in 2006. From what I had heard before that trip, the Aussies were a bit ‘EquA obsessed.’ Why would this method be better any other? And how could it really be true that everyone used the same method? During my visit to MiTek Australia I had a chance to talk at length to Andrew Scane, one of the MiTek sales and support guys there. He told me that the small size of Australia (population equal to Michigan + Ohio) had helped. Also, MiTek had promoted the use of this method, and supported in throughout its software suite there.

I asked more questions. I wanted to know if the EquA method was accurate. Was 23 commons really the same as 18.5 cathedrals? At some point, I realized that that wasn’t the point. Once you accept EquA’s as your unit of measure, once you just decide to trust it (like we do dollar bills,) a whole world opens up to you. Once you begin to do everything in EquA’s – estimate labor, calculate production capacity, price jobs, determine overhead, set profit goals, you are now living in a world that is much easier to comprehend and manage.

One Example – The Labor Rate

Once you can measure your work in EquA’s, you can determine plant’s capacity in terms of EquA’s. And once that has been done, you can measure your productivity by combining your overhead and direct labor, and dividing by your plant’s EquA capacity. So if you find you capacity is about 300 EquA’s a day and your overhead and labor is about $4,500 per day, you know your (non-material) cost of production is $15 per EquA. How does that compare to your competition? In Australia, you can just ask, because everyone measures in the same way.

MiTek Australia has written considerable documentation on how to make sure you are accurately calculating overhead, as you can see in the attached document. They actually provide a software program called Profit Centre that allows you to step-by-step enter costs (like those tax-filing programs we sometimes use) and use those figures to really see your overhead per EquA. It really is cool stuff.

Regrettably (I think) in the US, we have the phenomenon known as “no two customers do things the same.” Because of this, most of us have a much more fuzzy sense of our productivity and costs than the Australians do. To be fair, in the US we have a large variety of production equipment – it is more uniform (pedestals) in Australia. Also worth noting, in nearby New Zealand, preachers of the “EquA religion’ have not made many converts. Still, sometimes I wish I lived in a world where we all agreed to use the same “coin.”

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Things You Can Do With MBA

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Things You Can Do With MBA

MiTek’s Business Application (MBA)has grown a lot since its inception 15 years ago. That presents a problem, and several people I’ve talked to have said, “I know I’m not using all of its capabilities.” To help, I’ll present a short summary of its capabilities.

Overview

MBA enables a component manufacturer to keep records of all of the quotes and orders processed by the business. By directly reading the design files (trusses, wall panels,) the actual material used can be quickly and accurately summarized. Ancillary items, such as hangers, loose material, and any other items supplied can be added to quotes and orders. Using the wealth of information available about the components, labor estimates can be generated. Customizable reports allow the creation of quotes, production lists, and management reports.

Managing Your Business

You can get started with MBA with nothing more than a numbering system. However, the more information you store for each job, the more information you can get out of the system. Setting up customers and sales reps is a first step, enabling you to see how many quotes are becoming orders and tracking sales rep activity. Different markups can be applied to different customers or customer groups.

Classifying the job by type (Roof, Floor, Custom, Ag, Government, Multi-Family, etc.) allows you to look at subsets of your job mix. The more categories, the more you can examine the work you do and look for problems and opportunities.

Territories are an underutilized concept. You can use Territories for tracking your success in different markets, or set up loading territories so that you can make sure that the correct codes and loads are applied to the jobs delivered to a given area. Different tax codes and delivery charges can be linked to different territories.

Quotes and Orders can be stored separately, so that a record of the original quote is preserved even after extensive changes to the order.

Some of the most complicated customizations of MBA have been in labor estimating. Although the user can set up an almost endless variety of different schemes, custom programming is sometimes needed if you want to “look ahead” at the other trusses in the job to determine setup costs and labor.

Detailed analysis of individual orders and ‘summary reports’ of a group of orders can be done with the report writer. The reports “out of the box” are never enough for creative managers, who will always think of new ways to look at the accumulated data. Technical reps can make some changes to existing reports “over the phone,” and many customers have a person on their staff that has learned how to customize reports, and thus avoiding any delay in seeing how the ‘latest change’ on a favorite report will look.

As the Design Console

The MBA is best utilized as the “desktop” for all of your design work. Once a job or quote is started, you simply hit the “layout” button and MBA creates the job folder, launches the layout application, and keeps track of where everything is. This saves a lot of time when compared to creating the layout or the trusses first, and then having to ‘show’ MBA where the job is when you want to import the design work.

Comment or changes can be recorded in the job’s Call Log and minor changes (such as a delivery date change) are recorded automatically in the Change Log so the entire history of the order can be tracked. Attachments, such as a scan of the customer’s purchase order or photos from the job site can be attached to the order. The Job Navigator allows you to create customized lists for each user, for example a designer could have a list of “Work Assigned” to them, and another list of “All Orders Overdue to the Shop.”

Production Pre-planning

One of the most popular tools in MBA is called Build-a-Batch, which allows a user to organize all of the components in a job into production (table) groups. Once ‘batches’ are created, production paperwork can be generated for each group, including batch cutting. Build-a-Batch’s ability to see each truss, the quantity, span, pitch and visually ‘drag and drop’ into different groups makes the process very easy. Individual trusses can even have their quantities split into more than one group, if needed.

Although a simple “Delivery Date” field can be used for scheduling , a flexible Calendar Scheduling feature allows work to be assigned to the whole shop, or particular workstations. As work is added, a graph shows remaining capacity for each resource.

Other Tools

A set of standard trusses can be created, and used to create price lists or do “quick quotes” without having to (re-)do design work.

User security is managed in MBA, limiting access to defaults, making certain changes, and running certain reports.

A stand-alone Inventory module is available to help manage lumber and plates.

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