The Gibney Alliance has benefited from over 30 years of experience in the public and private sectors, across several industries and numerous operational environments. I have enjoyed tremendous opportunities to add value to so many wonderful organizations. Below are just a few.
A Project Extravaganza
Managing a project effectively requires a certain set of skills. Managing multiple projects enhances those skills. Managing over 150 projects over three years exposes you to almost every challenge imaginable.
The United States Government Publishing (formerly Printing) Office (USGPO) occupies a 1.5 million square foot office space in downtown Washington, DC., right down the street from the US Capitol.
As the world was moving from paper to digital publications, the enormous facility was emptying in a “Swiss cheese” fashion, with pockets of space throughout the facility. Two years prior, Congress had directed the agency to assess, develop, and implement a space-sharing initiative that would provide for revenue producing tenants.
General Frank Partlow, the Chief of Staff to Bruce James, the Public Printer appointed by George W. Bush directed me to take on the task of overseeing the renovation of the USGPO facility.
There were two components of the renovation. One, was comprised of projects that would reallocate space in accordance with the current and anticipated future needs of each department. This would entail a more efficient use of space throughout the facility and each department would also benefit through upgrades to equipment, services, and furniture. The second, complementing the first, addressed the Congressional direction to provide unused space to other legislative organizations. Ultimately, the space availed provided the United States Capitol Police, the Senate Offices, and the Sergeant at Arms with operations, office, and storage space merely four blocks from the Capitol.
- USGPO Visitor Center was established to showcase over a century of print equipment and artifacts.
- Three space-sharing agreements through the Architect of the Capitol (AoC) established, generating over $1.2 million in revenue annually.
- Innovative, vertically enhanced, converted rail spur furniture storage center, saving millions in transportation costs annually.
- Upgraded office environment for every employee affected.
- Excellent cooperation, across 19 unions, without any negative feedback.
- Letters of commendation from the US Capitol Chief of Police, and the Senate Sergeant at Arms.
- And finally, on my last day at the GPO, I was invited to the Capitol, where I was given a US Flag flown over the Capitol, in recognition of “support provided to the Architect of the Capitol.”
TiVO
Over 20 years ago, TiVO established itself as the leader in Digital Video Recording (DVR). They hold many of the patents on DVR features that most people take for granted.
Hughes Network Systems, TiVO, and DirecTV and the new Digital Video Recording (DVR) world.
Hughes Network Systems was the leader in HD technology, but its foothold and dominance was being threatened on several fronts. DirecTV was looking for a third manufacturer to accompany Philips and SONY to build their satellite DVR box.
Accompanied by a hardware and software engineer, I visited the TiVO Alviso facility to assess the viability of Hughes participation in the effort. My hardware engineer was sure we could build a better box, and my software engineer was extremely impressed with the TiVO team, and was thrilled with the potential to work with them. With the promise of securing the reference design if we were able to deliver 20,000 units by Christmas, I returned to Hughes recommending engagement. The leadership said, “Okay, you manage the program!”
- I had the opportunity to oversee the Guadalajara manufacturing facility and encountered 4,000 of the most wonderful, dedicated, and happy assembly line teams I have ever met, and their outstanding young manager, Daniel Gachuzo.
- Learned about deadlines and commitments, having to promise 20,000 unit delivery by Christmas, two weeks prior to the Black Friday advertising circular put out by Best Buy and Circuit City (RIP), with multiple risks of failure, i.e., manufacturing, test, packaging, demo development, and logistics.
- Delivered. Received the “Hughes One-Man Product Launch Award.”
- Achieving star status as featured TiVO unit in the showcase exhibition at the Consumer Electronics Show (CES), thanks to a fabulous design by a brilliant engineer, Alex Toh.
- Won the CES award for the Product of the Year.
IWO
Intercompany Work Orders (IWOs) provide the divisions of BAE the opportunity to take advantage of available resources from other BAE divisions.
BAE Corporation is a British owned defense contractor, formerly known as British Aerospace, with over 30,000 employees in the United States. Their growth, primarily through mergers and acquisitions, enabled them to become one of the biggest players in the US Defense industry.
While attending a leadership conference I had the opportunity to ask the President and COO, Walt Havenstine if he was familiar with the IWO process. He smiled and shook his head, and said, “Tom, that’s been in the works for over six years!” I responded, “Can you tell me to go fix it?” And he said, “Have at it – good luck!”
The Intercompany Work Order process, or IWO (Eye-woe), is the means by which one division of BAE could take advantage, and “purchase” the use of products or services from another division. The synchronization of the financial systems that were acquired or merged with could not keep pace with the rapid growth of the business, and what should have been a simple transaction was virtually impossible to complete.
In 2008, Intercompany Work Orders represented over $1.2 billion in revenue. And it was a “broken” process.
Bruce Jarvie, the BAE CFO was overseeing the project when I joined the team, and he introduced me to the lead, and told her I was taking it over. She was relieved, both literally and emotionally. This was a sideline task and just one of her many duties. Joining the biweekly call, it was quickly evident that was the case for every participant, and therein was the issue. Bruce realized he needed someone to bring it all together, and I was happy to do so.
It took a year to do it.
There were five or six different accounting systems that needed to be addressed, and the owners were located across the country, More than 50 stakeholders were invited to participate on the calls, and some were located in countries around the world.
The solution came down to tying the required inputs for each accounting system on the receiving end of the transaction to the output capabilities of each transmitting system. A digitally completed single page form was the answer.
In my local division, I established a team to develop a parallel process to document a standard template for implementing the policy. This is where “the rubber would meet the road,” and was keystroke guidance underneath a template for standardized execution. Every iteration was tested throughout the year-long process. When the final policy was signed and approved, the process was ready two weeks later.
- The lessons learned from this project were numerous, with the most significant being how to build an effective consensus across an incredibly wide variety of skills, interests, egos, and participation.
- Organizationally, I conducted a poll among the business developers and sales teams, all of whom had been frustrated by their inability to acquire resources from their own company! A very conservatively estimated impact was a $300 million annual swing from external to internal purchases of products and services.
- Bureaucratic failure at the highest level. Despite the CFO implementing the policy, partnerships between the divisions did not ensue. The powerful leadership among the divisions made “forcing” the change problematic.
- Sweeping change followed Linda Hudson’s appointment as the first female CEO at BAE. She led by example, cutting many leadership positions. That was followed by over 3,000 others, largely ignored in the news. I was one of them.
- I was asked to remain on the staff for another six months to complete another project, and during that time worked diligently to get a single division to partner on the process. When I left, I wrote to Ms. Hudson and offered her summary and recommendation.
- I never heard from Ms. Hudson, nor any of the other leaders I sent notes to for several years after I left, reminding them of this policy and the opportunity they were passing up.
Manufacturing Showcase
Innovation is often sought to enable a company to extend its capabilities. There are also times where innovation is the means of survival.
Racal Communications manufactured sophisticated handheld communications equipment in a very competitive, and top-heavy industry.
A British owned company with a very strong UK engineering team for support, Racal Communications was operating a handheld communications manufacturing facility with antiquated equipment. Most notable of these were “pick-and-place” machines, used for putting very small parts on printed circuit boards, and aptly referred to as dinosaurs. Upgrading the equipment would require millions in capital, which was not available.
As the Director of Manufacturing Engineering, I was very aware that we did not have the capital to purchase the equipment we needed to be competitive. Regardless, I encouraged my engineers to stay on top of trends in the industry, in the hope of eventually meeting this challenge. One of my engineers, Gabe Kenny, had cultivated a relationship with Mydata, a PC board equipment manfacturing company in Boston. They were seeking entry into the Mid-Atlantic region, and were prototyping a state-of-the-art machine. Gabe worked out a deal with them to bring their machine to Maryland, allow us to run it in production and replace out antiquated equipment. We would allow them to showcase it in our facilty and provide them the entry we sought, and enable us to improve our production efficiency beyond our wildest dreams.
- We were able to leverage Mydata’s presence to bring in similar showcase opportunities for three other high-end manufacturers of PC board assembly line equipment: an SCA screen printer, a Heller conveyor oven, and a Kwikclean board cleaner.
- This equipment enhanced our ISO 9000 registration, enabled us to win a $500M FBI contract over some of the biggest companies in the industry, and played a role in Racal winning the US Senate Productivity Award.
- I have a life-long friend in Gabe, who is also in my professional network, and, is one of the most brilliant Operations experts I have ever known.
Estimating the future
Initial estimates provide the basis for planning project success. Refining those estimates to constantly update cost, schedule, and quality are the key to achieving that success.
EATON Corporation’s $3B B1B contract fell under MIL STD 1567A which required engineering standards for every product. This included my department, microelectronics. This requirement was also part of the contracts I worked on at Fairchild Space and Defense.
Engineering standards development was my first exposure to the need for an artistic component in a scientific effort. There were no text books, guidelines or programs for standards development in microelectronics manufacturing, so I had to develop them. Using the Maynard Operations Sequence Technique (MOST) as a guide, I developed a means to scale floor operations to microscopic assembly. I received a personal commendation from Zjell Zandin, the tool’s creator, for my work.
My work at EATON opened many opportunities, and ultimately I chose Fairchild Space and Defense. Using an approach similar to the one used at EATON I generated a program for estimating manufacturing, test, and inspection labor for proposals. It incorporated learning curves, weighted product similarities, and production breaks – to accommodate IDIQ programs. In addition, I collaborated with 11 departments to use past performances to extrapolate their support. Once completed, I conducted a department by department review of the proposed labor requirements to make any unique adjustments for specific contracts. Finally, I wrote a supplemental tracking program that used the proposal information, including any post-award adjustments, to monitor the program through its contract life.
- The proposal estimating development system reduced the initial development time by 75%, and revisions – a constant issue with IDIQ contracts – by 97%.
- The program was used by Fairchild and SMITHS the firm that bought them, for over 15 years after I left.
- I was able to customize the program for use in three other organizations.
- It provided an understanding of the value of estimation, and ultimately enable me to use it as a tool for explaining that value to my management leadership and my customers.