So we did something stupid. Capacity planning is manufacturing 101 and we forgot to do it. What's worse is I was recently interviewed by The Startup Foundry and foolishly explained that we wouldn't have trouble scaling. I was obviously wrong.
The problem is, we initially thought we'd scale by just buying more of the machinery we already own. The downside to that strategy became apparent as we started to grow exponentially. Our current low-end equipment is labor intensive (i.e. slow) which means we'd need to buy a few more machines and also hire additional people to keep up.
Our other option was to look at high-end equipment (i.e. something faster) that'd let us pump out more work without expanding our staff. That strategy has 2 problems: 1) we had not done much research on high-end sticker printing equipment 2) high-end equipment is more expensive and we have limited funds.
Obviously, this wasn't something that we wanted to rush into, but we also needed a solution ASAP. Rather than screw around any longer, we decided to get on a plane and visit a handful of machine vendors to learn what's available. It's not fun investing in equipment when you're under pressure to make a decision, but we just bought some awesome new machines that we're confident will pay off. The bad news is that they won't be operational for 8 more weeks. :-/
In the meantime, here's what we're doing to minimize disappointing our customers:
- All products were updated to notify you during checkout that production time is 15 business days.
- We added a warning during checkout to notify you that deliveries are not guaranteed.
- We organized our internal operation to run 3 full shifts, 7 days a week.
We tend to think that the best thing we can do at this point is be honest about our situation. We definitely don't want anyone placing orders with us only to be disappointed. If you have any thoughts on how we can do better leave a comment or send us an email.