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Production Problems
I run a small specialty shop focusing on Subarus primarily and Saabs as a second brand. Since we specialize many of our projects are heavy line work including many head gaskets and engine repairs. My business has been growing and I have a strong ability to sell the work once I make contact with a potential customer. I keep a fair amount of speciality parts on hand to avoid time delays running to the dealer.
Over the last 18 months as we have grown I have experienced a trend of my techs never staying on schedule. I have changed master techs three times with the results being the same. The schedule gets stretched no matter what — I manage to meet payroll but my family always gets squeezed — I rarely get paid. I have tried flat rate and hourly with the same result. The issue seems complex with many factors adding to the problem — including poor time management, selecting some bad jobs to take on, unexpected issues, and the cars generally fighting us due to age and wear and tear.
My current master tech is a wonderful person with a terrible sense of time — quality is very important to me but the level of detail at times is overboard. I fear I can’t change a tigers strips here. He knows of my concerns and tries to focus. We have a daily schedule that we discuss but its not worth the paper its printed on.
So as the work is piling up and cash flow is tight — we have $11,000 of work sitting on the ground today and growing but it does not get out and little in the bank — I fear if I add more techs and lifts the problem will grow exponentially. I have a master tech and a junior tech working for me. My evenings and weekends are getting tied up with the missed deadlines while my techs get paid and take weekends and holidays off.
I know it’s my business but I try to be very collaborative with my team — yet at the end of the day these guys are doing pretty well while I’m personally sinking. Any guidance would be helpful because I’ve run out of ideas. This issue is probably the hardest business problem I have ever tried to grapple with.
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