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Steve Williams Writes a New Chapter
November 25, 2013 | I-Connect007Estimated reading time: 6 minutes
Steve Williams has spent his entire career learning the best ways to manufacture high-quality products. Now, he wants to pass on that knowledge and experience to his clients through his new venture--Steve Williams Consulting. He recently spoke with Editor Ray Rasmussen about the newest chapter in his life.Ray Rasmussen: Steve, how’d you get into the PCB business?
Steve Williams: Like many of your readers, I grew up in this business. I cut my teeth (and more than a few appendages) in this industry working for the family PCB manufacturing business. This was well before the advent of CNC machines, automated plating lines, and statistical process control. I remember manually bending electronic components after [grade] school for an assembly customer; I think getting paid a penny per part. I've been extremely proud to see this business grow into the professional industry and key part of the overall electronics industry it has become.
Rasmussen: Where have you worked and what did you do? What’s your background?
Williams: Well, Ray, for the past 15 years I have been the strategic commodity sourcing manager for Plexus, a large EMS provider. My team managed the supply base for anything that was custom engineered: PCBs, metals, plastics, wire harness, mechanical assembly, etc. Prior to Plexus, I spent 22 years manufacturing PCBs, holding director-level positions in quality, engineering, manufacturing, and operations.
Rasmussen: Why?
Williams: PCBs are in my blood. I started my career in the family PCB business learning manufacturing from the ground up (I started by manually deburring drilled panels), and, as many of your readers know, once you're in, you're in for life!
Rasmussen: What made you leave your long-time job with Plexus to venture out on your own?
Williams: My true passion is helping companies interested in "Getting to Great." Over the past 10 years I have published close to 100 articles on a variety of business topics centered on that very thing and have published books on Lean and quality to hopefully be used as a resource to not only improve discrete companies, but the industry as a whole. I grew up in this industry and I am personally vested in its survival.
I've spent the last 15 years evaluating manufacturing companies all over the world; assessing technology, quality systems, and Lean practices. The decision to start Steve Williams Consulting was born out of the frustration of being limited in the amount of help I could offer companies due to the conflict of interest that comes with working for a large public company.
Rasmussen: What’s the state of manufacturing as you see it?
Williams: As you well know, through my articles for your magazines, I have been very vocal about sounding the alarm on the state of U.S. manufacturing; I just don’t see enough jobs being created in the traditional manufacturing trades to keep the existing business we still have. For every three machine operators, CNC programmers, welders, metal and plastic workers and machinists retiring from the workforce, only one new one is entering. That is not sustainable.
Rasmussen: Being PCB sourcing professional for 15 years, you have a unique perspective. Where does the U.S. industry stand today and where’s it headed?
Williams: In 1990 there were roughly 1,000 U.S. PCB manufacturers, in 2000 there were 700, and in 2010 the number of domestic shops had fallen to only 365. Unfortunately, I fear this number will be below 300 by the end of 2015; a short two years away. Military and intellectual property-sensitive markets should continue to support U.S. manufacturing going forward. Where the U.S. market really needs to continue to compete are QTA/proto business, advanced technology, and short run orders.
Rasmussen: You wrote a book on Lean and recently on quality. Where did you get your training? What makes you an expert?
Williams: Expert is an interesting word, Ray; one of my early mentors once told me “Steve, an expert is merely someone who lives more than 100 miles away!” The real answer can be broken down into two parts: 1) These two disciplines have always been a part of my DNA, and many of my early successes came from combining Lean and quality to achieve operational improvement and 2) over the past 15 years I've been directly involved in evaluating the processes, technology, and performance of literally thousands of companies across multiple industries. This experience has given me intimate access to see the best-of-the-best and also the worst-of-the-worst. I feel that this unique experience combination gives me a perspective and offering that hopefully will be of value to companies.
Rasmussen: Tell me about your consulting business.
Williams: Thanks for allowing me the plug, Ray. The name of the company is Steve Williams Consulting LLC, and there are three service offerings:
Lean & Continuous Improvement: My underlying philosophy is that the success and growth of an organization is based on the belief that every facet of the operation must continuously improve. Review how we can assist you in developing your Lean and continuous improvement programs to drive operational excellence in your company.
ISO/Quality Management: Whether you are pursuing ISO certification, or looking to improve your existing quality management system, we can help. Let us show you how to simplify the process, meet requirements and improve your company’s quality levels.
Strategic Sourcing: Review how our thought leadership and extensive global perspective and relationships can help you develop a world-class supply chain that will improve your bottom-line. See how to utilize our technical and quality expertise as a cost-effective extension of your company to troubleshoot quality problems.
Rasmussen: How can you help companies achieve excellence in manufacturing?
Williams: My philosophy is that sustainable solutions can only be achieved by creating a collaborative environment in which employees become part of the solution. My style is a “roll up my sleeves and get my hands dirty” approach to develop a customized solution that fits each specific company’s needs. This collaborative approach assures that employees not only buy-in to the solutions, but take ownership and become champions of the cause. Through education, coaching, and facilitation, I will train a company’s employees to become active solution leaders capable of managing sustainable, permanent change.
Rasmussen: What does this process look like? What are the steps?
Williams: I have developed a simple four-step process:
Step 1 - Expectations. Meet and align on project scope, level of engagement, and deliverables.
Step 2 - Assessment. I will perform a detailed formal assessment of the current state of the project with a hands-on approach working closely with your employees, systems, and other available resources.
Step 3 - Recommendation. Formal presentation of recommendations customized to your business needs based on my three decades of best practice experience.
Step 4 - Execution. I will work with your internal team to guide them through implementation of the recommendations through focused coaching, education and training that will allow them to own, manage, and sustain the change. Rasmussen: Thanks, Steve.
Williams: Thank you, Ray, for the opportunity to talk about my new company. As you can see, I am extremely excited about the potential to help our industry not only survive, but thrive. Am I providing a viable product that companies will recognize a need for? I believe so, but only time will tell. What I do know is that I am passionate and committed to helping companies that are interested in "Getting to Great."
Steve Williams is president of Steve Williams Consulting. He can be reached by calling 920-841-3478 or e-mailing steve@stevewilliamsconsulting.com.