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Almost immediately they send him down to Malaysia to
run one of their ailing textile factories. He has no
experience in the garment industry, no formal management
training or experience, and is not only unfamiliar with
Malaysia but has in fact spent the last decade living
outside Asia.
"When I first walked into the factory," says
Harry Lee, "I'd never even seen a spindle before.
But there I was in charge of a factory of 600,000 square
feet, 3,000 employees, 90,000 spindles and 1,500 weaving
looms. And it was losing a million Malaysian dollars
a month."
It took just six months for the young electrical engineer
to get the factory to break even point, and on the fast
track to becoming a successful, profitable business.
The experience was the beginning of a lifetime of achievement
for Harry Lee. The young engineer suddenly found himself
at home and comfortable in a new world far from laboratories
and theories. And although he never went back to engineering,
the working procedures, techniques and thinking processes
he had cultivated as part of his engineering training
provided a remarkably effective foundation for his future
business success.
"For example," he says, "when I first
arrived in that Malaysian factory it was chaotic. There
were no systems, no training, workers were using identical
machines in completely different ways. A mess. There
was a group of Japanese technicians looking after some
of the new machines, and they'd come around and say,
'That's not right, that's not right', but nobody took
any notice of them. I took them aside and said, 'Write
down the ten things we need to do most urgently to solve
these problems. Not eleven, not nine, just ten things.
Then, when we've corrected any one of those items so
that you're satisfied it's right, cross it off the list
and add one more.' One of the first things to come from
that was a training scheme that taught all the workers
to use their machines in the correct way. Needless to
say, productivity increased dramatically.
"And I asked questions all the time. 'What's this?
Why are you doing this?' I wouldn't take the first person's
answer. I'd keep asking the same questions again and
again to different people, then try to make a logical
deduction: 'Which of these answers seems to be correct?'
And as I had no idea what was wrong, I'd simply ask
the staff to tell me what was wrong. It's crucial to
identify the problem-or perhaps it's a whole range of
problems, or maybe even an interlocking network of problems-before
you can work on a solution. When I came up with a solution,
I'd also test it by asking people questions: 'Will this
work? Is this the best thing we can do in this situation?'
You start to gain an understanding of what's happening,
and what really needs to be done.
"It is part of my background. A lot of engineering
is about confronting problems and arriving at the best
solution-which often isn't the one you expect in the
beginning. To understand problems, my professor at Brown
(university in the USA) made me ask questions all the
time. Now it's something that I always do. And it helps
that I'm very patient. That's also part of my engineer's
nature."
Patience certainly helped Harry Lee with his next challenge.
With the business in Malaysia running smoothly, Lee's
family decided to utilize his skills in Thailand, where
their company, TAL (Tal Apparel Limited), had two garment
factories. The day before he arrived, one of them burned
down.
"My job brief suddenly changed somewhat,"
says Harry Lee with a smile. " The first priority
was not to run the factory-I had to rebuild it."
It turned out that the premises were insured by five
different insurance companies, and negotiating with
them all in the convoluted business environment of Thailand
at that time was certainly a test of patience as well
as skill. But within nine months, the factory had been
rebuilt, and was running successfully. With his mission
accomplished, it was time to move on to new challenges.
Zero inventory
Harry Lee returned to Hong Kong at the end of 1979
to join TAL's garment manufacturing division. Despite
the fact that the family business had extended through
Asia and their manufacturing base was very strong, he
soon began to notice areas of operation that he felt
could be significantly improved. One of these was improving
the speed and efficiency of the supply chain flow of
orders, from manufacturer to customer, in order to reduce
the client's need to carry inventory.
"The ideal," says Harry Lee, "is zero
inventory. Carrying excess goods in a big warehouse
hurts everyone. The wholesalers and retailers are gambling
on their orders being right, they even have to buy more
stock than they need to cover themselves, and they have
to pay the cost of the warehousing. The result is a
big mark-up in the price of the item, for which the
consumer pays. The adverse results for wholesalers and
retailers are seen every year in seasonal sales in which
items are offered at loss-making prices simply to liquidate
huge amounts of unsold stock.
"Electronic systems-computers," says Harry
Lee, "have the potential to do away with inventory.
Ideally, you should only order what's purchased by the
consumer, the end user. We have the technology to make
things like garments very rapidly after they're ordered.
Think of days gone by in Asia when garments were made
by tailors, and the customer simply chose the style
and the fabric. But the tailor only had one or two simple
sewing machines. These days garment factories have hundreds,
even thousands of sophisticated, specialized high speed
machines, and a well-designed computer system can control
the ordering in seconds from anywhere in the world."
It took many years-and much steady development-before
Lee was able to see his "zero inventory" concepts
start to come to fruition. But by 1995 he had convinced
one of the largest retail chains in the USA, JC Penney,
to try his methods. Every cash register in Penney's
garment stores was linked to computers in TAL headquarters
in Hong Kong. The moment a garment was purchased in
the Penney's store the order was recorded in Hong Kong,
and a re-order instantly passed to the appropriate garment
factory in Asia, along with shipping instructions. Just
a few days after each transaction, a replacement garment
was on its way to the store where the original garment
was purchased. Though still falling a little short of
the ideal "zero inventory", it enabled Penney's
to vastly reduce the stock they carry, to minimize wastage
and error in their ordering, and to reduce prices while
increasing profit. Penney now uses the system in all
their stores in the USA, and other retailers, including
LL Bean, are starting to take advantage of it. Though
few people know their name, TAL has become one of the
biggest garment manufacturers in the world (eg an estimated
one in eight dress shirts sold in the USA are made by
TAL.)
Flowing the numbers
TAL's success has also made them a shining example
of a local company using the full potential of e-commerce
systems to achieve global success. Lee is quick to point
out that this was by no means an easy, or straightforward
process.
"In the beginning," he said, "we started
out doing what everyone else did: introducing computers
into one division at a time, and then when we wanted
to link them, finding that they wouldn't talk to each
other, we had to re-do the whole thing. But we worked
at it, and we started to get it right.
"The ideals that I seek are to be completely paperless
and to have a shared database where information is readily
available to everyone who needs to use it. By paperless,
I mean the information needs to be able to flow directly
into the system in electronic format. That not only
reduces input time and inefficiency, it minimizes the
chances of introducing errors. It's fast and efficient.
Then the information needs to be available so anyone
can extract it and use it as they wish. There's a lot
of ways you can look at information, you can see things
that others mightn't see, do the things you need to
do much more effectively.
"That doesn't mean you need a massive computer
set-up, or even that I advocate vast computer systems.
It still all happens in the mind. Technology is just
a tool. It's the attitude, the willingness to use the
tool properly, and to see just how much it will really
do for you, that really counts. It's also essential-absolutely
essential-that if you're going to make the most of the
opportunities offered by e-commerce your business is
properly set-up for it, both the internal systems and
operations as well as the external activities.
E-commerce is not just something that happens when
you decide to take your goods or services out of your
factory or office. It's a complete, integrated way of
working, and every part of your operation has to be
correctly set-up for the work it has to perform. That's
more about business management than computers.
"And as for the size of systems, there is so much
good hardware and software out there, even a small SME
can get well set up for a minimal investment. And if
you take the right approach even simple spreadsheet
programs give you the opportunity to extract information
and look at it in many different ways, which inevitably
results in a much better understanding of what's going
on."
Linking the future
Harry Lee's passion for e-commerce inevitably brought
him into contact with Tradelink. TAL quickly became
one of Tradelink's best customers, and the two companies
developed close commercial ties. Recently, Lee was named
Chairman of the Board of Tradelink, and is looking forward
to the new challenge-and the opportunity to bring e-commerce
to more businesses in Hong Kong.
"Our primary goal," says Lee, "is to
create a situation where essentially all trading operations
can become completely paperless. This means a vast network
that links everyone from banks and the Government through
to transportation and shipping companies, manufacturers,
retailers, importers, exporters-everybody. The whole
spectrum. That alone will mean big savings, but it will
also create a system that offers unprecedented efficiency
in operations.
"That's a big goal" concedes Lee, "
a big challenge. And it's just the beginning. But then
my motto has always been, 'Anything's possible.'"
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