Information, Computer Systems and Manufacturing

The Problem Listing computing costs as overhead is leading corporations to make budgetary decisions that are counterproductive to the best interests of the company. It is time to recognize that information and its accurate, timely delivery throughout the organization is as critical to business success as are raw materials and labor. It can no longer be considered as overhead.

Background
Does this seem to be a radical view? Consider the following. Classically, the ingredients for manufacturing have been labor and raw materials. But you could put all the raw material you need into a room with all the labor you need and still nothing would be produced without providing instructions as to how the labor resource should be applied to the raw material. That information, along with its delivery mechanisms, is as much an essential input to the manufacturing process as are the materials and labor. And yet this has never been recognized in "classical" manufacturing theory.

When Adam Smith discussed the production of needles in the mid 1700's ("An Inquiry Into the Nature and Causes of the Wealth of Nations"), manufacturing was typically done by individual craftsmen who performed all the processes themselves. They acquired the process knowledge by passing through an apprenticeship program. The Industrial Revolution would soon change this, but the concept of "information" as an entity would not arise until 200 years later.

Frederick Taylor recognized that the knowledge about a process could be documented and organized, ("Principles of Scientific Management") even if he did not see that knowledge as "information" in the way we do now.

Henry Ford, implementing the concepts of Taylor's Scientific Management, created the assembly line with the idea that operations could be defined and standardized to the point that minimal training would be required for any worker. The place in the line determined the task to be done and the line could be staffed with practically anyone off the streets. The critical information about what was to be done in what sequence was virtually "hard-coded" into the factory floor.

As products became more complex and varied, the rigid assembly line was modified to accommodate the changes. It became the job of the supervisors or shop foremen to direct the activity of the labor force as production requirements changed. These supervisors became the delivery mechanism for the process-directing information.

In today's environment many of our products are customized, and the configuration requirements are delivered to the shop floor via computer systems. The process knowledge is no longer built into the assembly line; it is dynamic data that has its own delivery mechanism. Without this information, the manufacturing process would stop, regardless of the availability of materials and labor. And yet that information and its delivery systems are considered overhead, a necessary evil whose costs are to be minimized. The costs are not tied directly to the company's products. How did this situation come about?

Computing first found corporate life through accounting and has been viewed, like accounting, as an overhead function, providing a trail of information to document what has already occurred. That use has changed over time but it has changed so gradually that no one has taken conscious note. Computing systems now communicate what will be done in an organization, from product design and order processing through JIT, process scheduling and upgrading of delivered products. The information being delivered actually directs the operations of the organization. The information delivery systems constitute a control mechanism that can dynamically reconfigure the manufacturing process in real time.

The importance of computer-delivered information can be gauged by the reactions of our users. We are being asked to deliver more systems, not fewer; support more complex processes, not simpler ones; provide quicker response time, not slower. They see these systems as mission-critical, not "frills." The fact that users are concerned about response time, let alone availability, gives further credence to this view.

It is time that information be recognized as essential, without which manufacturing cannot take place. It is not a pure overhead item, it is an ingredient of the manufacturing process. Continuing to account for it as overhead can and does lead to contradictory decisions by management.

An Example I will not embarrass my present or former employers by telling war stories, but I know the following fictitious scenarios will be familiar to many. A company decides to make radical use of computer technology in designing and building a new product. Great things are predicted for the quality and efficiency that will result from making the switch from the old manual processes. But before long the cry goes up from management, "Overhead costs are out of control! They are 77% higher than for comparable programs! We must get these costs under control!" Budgets are cut back, people are laid off and support for existing systems is reduced. Backlogs increase, morale declines and the company loses efficiency because the computing systems can't keep up with the demand. This situation would not have arisen if the computing costs were recognized as an essential part of starting up a new program. Would there have been the same concerns if material costs were up due to the use of advanced materials? I think not.

How often have we heard that the slow response time from a system is jeopardizing the success of a project or new corporate initiative. Is it logical to claim that slow response on an overhead item could have that much impact?

These are only two examples. I'm sure people can find comparable situations in their own companies. We have all seen it happen, but what can be done about it?

The Proposal Obviously not all information systems are directly related to the manufacturing process. Computerized systems support almost all functions of a business, including overhead functions. It therefore becomes necessary to distinguish between these systems.

I propose that information systems be classified as either directive or non-directive. A directive system is one which is used to direct the processes or activities in a proactive sense, identifying what is to be done. A non-directive system is one that tracks activity or resources and reports on it after the fact. While I believe that information is as much a "basic ingredient" as raw material and labor, we don't currently have a method of quantifying information in a way that would allow us to treat it as a direct cost. A more realistic proposal is to classify directive systems as factory overhead, while non-directive systems would still be classed as pure overhead. When information from a non-directive system is used as direct input to a directive system, the non-directive system should be reclassified as directive. The information flow is the determining factor.

Benefits Recognizing the contribution of information delivery to the manufacturing process will provide a much more accurate picture of manufacturing costs and efficiencies. We could identify the impact and benefits of approaches such as Digital Pre-Assembly by tying them to the processes which they support.

In addition, the value of directive systems could be depreciated over the expected life of the system in the same way that machinery costs are depreciated. This would provide visibility to the fact that information systems have a finite life expectancy and the company must plan for their maintenance and eventual replacement.

As an aside, identifying the life expectancy as part of the cost-benefit analysis would also provide valuable insights into the viability of a project and encourage long-term thinking. A more dynamic environment would dictate a shorter design/build cycle in order to maximize the window of opportunity. It would be inappropriate to spend three years developing a system when the business environment life cycle in that area is only five years.

The Challenge Such a change would not be made easily. A more complete definition of "directive system" would have to be developed, along with a way to evaluate computing systems under those criteria. Depreciation schedules would need to be established in accordance with tax laws. The true use of computing systems would need to be identified. These are not simple tasks.

However, the challenges we face are constantly increasing. We are moving into an age of customized products from an age of standardized ones. Market forces are demanding quicker response and more flexibility. These challenges can only be met via directive information systems, but we must be able to accurately associate the costs of these systems with our production environments.

There is increasing recognition that we are becoming a knowledge-based society (Peter Drucker, "Post-Capitalist Society") and that many of our processes (business, political, educational and societal) will be undergoing profound changes. We cannot continue with "business as usual" and expect to make correct decisions if our way of viewing our world is inaccurate. We must have an accurate picture of the factors in our environment and an accurate understanding of how our decisions affect our businesses. The "rules" regarding information systems are not written in stone. We are dealing with a new and unique technology, and our way of viewing it must change.

 

Email me at me@gordon-glasgow.org