Operations systems for small manufacturers

One person quits on Friday.
What happens Monday?

Monday the dock waits to be told which pallets go on which truck, and somebody senior does the end-of-day report by hand. Every plant has a position like that — one that wouldn't exist if a spreadsheet could do it.

Find your bottleneck — free 3 minutes. No call required.
Watch the system run — 3 min
Three minutes on our own floor.
$60,000Per position, per year. Several designed out of the org chart.
2,000 hrsA year of supervisor paperwork. Another position's worth of hours.
+15%Shipments out the door, same dock crew
InstantRecall trace. Pushbutton, and it used to take most of a day.
Annual figures, every one measured after go-live.
What this is

I find the one manual process costing your plant the most, and replace it with a system you own outright.

The job I eliminated compiled pick tickets, typed the bills of lading, and sent the customer an end-of-day production report. All of it lived with one person. Now the system builds the tickets and the dock works off a tablet.

I am an operations manager. I run a plant floor Monday through Friday. I built that system for my own building because nobody was going to come build it for us.

On adoption

“My guys aren't computer people.”

Mine weren't either. The people running that system are adults with learning and physical disabilities working in a sheltered workshop. Tablets, barcode scanners, live production data, every day for more than a year.

What made it work was that the floor got to tell me what to change, and I changed it. Adoption turned out to be the easy part.

How it works

Three steps, and you can stop after any of them

Step one

Discovery

$2,500

Two days on your floor watching the real process. You get a written system spec and an ROI model, yours to keep whether or not you ever hire me to build anything. Credited in full against the build.

Step two

Build

Fixed fee, from the spec

Paid in three milestones. The second comes due after a working version is running in your building, with your people, on your real data. Stop there and you keep what's built plus the documentation.

Step three

Care plan

$450 / month

Monitoring, fixes, and two hours of change work every month. Optional, cancel any time. Hosting runs $25 to $50 and you pay the provider directly, so there is nothing for me to mark up.

Before you ask

“What happens if you get hit by a bus?”

It is the right question, and you should ask it of anybody who builds you software. Here is how I answer it.

The database
Your Supabase project, on your account and your card.
The source code
Your GitHub organization, from the first commit.
Documentation
A contract deliverable. Data model, business logic, and the edge cases that will bite whoever comes after me.
Your data
Exportable any time, without asking me.

You are buying an asset that happens to have been built by me.

Worth a conversation

  • 10 to 200 people, making or moving something physical
  • One spreadsheet that one person maintains
  • You bought software a few years ago and half the floor works around it
  • A customer audit wants documentation you don't have

I'd tell you to save your money

  • An off-the-shelf product already fits how you run. Buy it, it's cheaper.
  • You want your whole ERP replaced. That is a bigger firm's job.
  • Nobody on your side can give me two days to watch the process.
  • You need it live in three weeks.
Free · 3 minutes · no call required

Find out what your bottleneck is costing you

Answer six questions about how your floor runs. You get back a written read on your three most expensive manual processes and roughly what each one costs you a year. I email it to you and that is the end of it unless you write back.

Goes straight to joseph@buildsolid.biz. Anything you put in here stays between us.

Who you'd be hiring

Joseph Howell

Operations at a manufacturing plant in St. Joseph, Missouri. Twenty-two years in the Army before that, retired senior non-commissioned officer. I live in Kansas City.

I still have the day job and I am not going to be cute about that. It is most of why I am worth hiring — I am in a building like yours every weekday.

I take one build at a time, on purpose. If I am already in one when you are ready, I will tell you when I am free.