Tag Archives: Lowe’s Companies Inc.

Tech Talk: Warehouse Management System Aids Hardware Firm

McLendon Hardware, based in Renton, Wash., started in 1926 and has now grown to six stores throughout the Seattle-Tacoma region and a 90,000 square foot warehouse. When the warehouse became overcrowded and inefficient, Vice President Mike McLendon tells IncTechnology.com that tracking goods in a warehouse management system (WMS) with radio frequency (RF) barcode reading equipment produced dramatic results. Elizabeth Wasserman: Why did you decide to deploy a warehouse management system? Mike McLendon: We were using a general enterprise resource planning (ERP) system for all other functions in our stores — point of sale, accounting, accounts payable, etc. But we only had limited computer functionality in our warehouse. It was very manual driven. We worked from a big list. We would go pick the items we needed to send to our different stores and manually check them off the list. We couldn’t track inventory accurately using this system. It really drove us to look for something different. Wasserman: What type of business benefits were you looking for? McLendon: We’ve been in business 82 years and had a warehouse for a long time. In the past, we didn’t care about having an accurate inventory of our stock on hand. We ordered a lot of stuff and made sure we had enough when customers asked for it. These days, however, we compete against Home Depot and Lowe’s. The reason customers come to us is because we have larger quantities on hand and more types of different products than Home Depot. We’ve always strived to provide the best service and broadest selection of products available. But as we’ve grown, so has the number of products we sell. To manage that number of products it became so difficult that we realized we had to manage our inventory better. Near the end of 2005, we decided we had to do something, so we started not stocking as many things in the warehouse. Some goods we would have shipped directly to the store, so we wouldn’t have to manage so much stock. By 2006, however, we realized that we still didn’t have as much information as we could get from using computers. That’s when we decided to look for a warehouse management piece of software. We decided on PathGuide Technologies’ Latitude WMS, which we integrated with our ERP system. It went live in January 2008. Wasserman: There’s been a move among businesses recently to move toward lean inventory. Were you impacted by that at all? McLendon: That was one of our earliest phases. We decided to see if we could manage better by being leaner in terms of the amount of inventory we had on hand at one time. Do we really need to stock all this stuff in the warehouse? Or should we ship it to the store and let them stock it? We did that with some of our products. That relieved some of the pressures on the warehouse as far as being overcrowded. But it was not the only thing we needed to drive efficiencies. We didn’t have a means to automate our ordering. Every time we’d place an order, we’d have to go out and count how many we had and write that order up and fax it to the factory. A very slow and tedious process. To increase turns and lower stocking levels we wanted to be able to place orders on a more frequent basis. We have the ability within our Eagle ERP system, by Activant, to create orders automatically. But to use the automated ordering function requires that you have precise on hand quantities. By adding a warehouse management system one of the things we have now is an accurate inventory in our stores and warehouse which provided us the ability to automate our orders. Wasserman: How does your new system work? McLendon: It’s extremely easy to use. That’s one of the reasons we chose it. The nice thing about a warehouse management system is it only does one task. The system itself has three parts. It has a database that holds all the data. It has a gateway server that handles communications between the database and the radio frequency equipment.  And the third part is radio frequency equipment. Most products come pre-labeled with barcodes. We have handheld RF guns that read the tags when we check in inventory and when we pick goods to ship to our stores. We have access points around the warehouse that allow the RF guns to talk to the database. The telling point for me after it was installed was that my Dad, who is 78 years old, could use it.  He has his own RF gun and works with the receiving crew to scan the stock in. Once you scan the goods into the system, the computer knows where the stock is. It makes it much easier to pick products to ship to our stores. When you go over and take four of these products, you scan that information in and it registers in the warehouse management system. It makes it all function paperlessly. In the old way, we would take a piece of paper and a shopping cart down the aisles of the warehouse and throw the goods in the basket. We never had to check off anything or worry that we were taking more than we should. The downside was that we never knew how much we had or where it was located. Back then we used what we called “tribal knowledge” to locate items.  Longtime specialized employees who were the only ones who knew where everything was. Wasserman: What have the results been? McLendon: We are very satisfied with results we have gotten by combining the functionalities of the warehouse management system with those of the ERP system. Our picking rates have increased by 50 percent within the warehouse. No more tribal knowledge. We can train anyone to pick in one day. And our inventory accuracy has increased from 65 percent to more than 90 percent. At the same time, we’ve reduced our inventory level by about 10 percent. In terms of what our customers see, our out-of-stock situation in our stores has been much better. We have actually decreased out of stocks by 10 percent at the store level. Our goal is to have better than 99 percent in stock. Now, we’re at around 95 or 94 percent — in some stores it’s a little better and in others it’s a little worse. We want it to creep up so that we don’t lose the sale because we don’t have an item in stock.

39 Great Business Bargains

Online Payment Processing If you don’t need a full-blown e-commerce solution, PayPal lets you accept credit card payments with a PayPal shopping cart. There are no setup charges and no monthly fees, just a transaction fee of 2 to 3 percent, plus 30 cents–about what credit card merchant-account processors charge. Payroll Services Outsourcing onerous payroll tasks is easy and quite affordable. For a flat monthly fee, online services such as surepayroll.com and paycycle.com do all the calculations, pay and file federal and state taxes, and make direct deposits into your employees’ bank accounts. PayCycle costs $45 to $73 per month for a company with 25 employees, regardless of how often you run payroll (50-employee maximum); Sure Payroll charges about $87 to process the monthly payroll for 25, and can cut payroll expenses by up to 50 percent. Playing Post Office All mail is not created equal, so if you’re paying equally for all of it, you’re probably paying too much. Go to usps.com/businessmail101 for a primer on the different classes of mail and an explanation of the many discounts available for bulk and presorted mail and for things like dropping mail off at a bulk mail center or a central post office. For flat non-letter-size mail, such as catalogs, simply presorting according to Zip code can save you up to 30 percent on postage, and you can save up to 10 cents per pound by dropping it all off at a bulk mail center. And remember, never send a letter if a post card will do–post cards cost 38 percent less to send than first-class mail. Montblanc Pen: because you don’t want to sign a multi-million dollar contract with a 50-cent pen Seal the deal with a more elegant instrument. Pen maker Montblanc distributes its wares through a small network of authorized dealers, so prices are pretty standardized. A new Montblanc StarWalker Ballpoint sells for $216, including shipping, at writewithstyle.com. That’s not a bad price, but you can do better. The recent eBay price was $142, with shipping–with several more up for bidding. Color, light, and air A fresh coat of paint might be the most cost-effective investment you can make in the look and feel of your workplace. And since paint is so cheap, you can always repaint if you’re not happy. For help finding a color scheme, do what professional designers do: Check out the free color forecasting reports published by the Color Marketing Group. To make sure your new color looks right, switch out harsh white fluorescents with “warm white” ones; their fuller-spectrum light will make everything look better. Finally, improve the indoor air quality with bargain-priced planters from big-boxers such as Lowe’s and Home Depot, warehouse clubs, or Ikea. Carpeting Buy or lease modular carpet tiles, such as those made by Interface. While regular roll carpet is cheaper to buy up front, modular tiles can pay off in the long run because rather than having to buy a whole new carpet, you can just replace the worn tiles. It’s easy to take the tiles with you if you move. Plus, they look a lot cooler. Software Put off software purchases until the end of the year, when you’ll find discounts on programs that are being released in new versions. You may also see discounts at the end of a financial quarter. There’s also plenty of free software out there available for download–from e-mail (Evolution) and e-commerce (osCommerce) to Web browsers (Firefox, Opera) and accounting (GnuCash). Two of the best sources of freeware are tucows.com and CNET’s Download.com. Cheap (and Eager) Labor Entrepreneurship is hot these days, and plenty of students are eager to get experience at growing companies. The key is to offer experiences that truly can’t be had at big corporations, such as real responsibility, individual mentoring, and access to decision makers. William Wright-Swadel, director of career services at Harvard University’s School of Arts and Sciences, suggests that companies build long-term relationships with career centers at local colleges and market themselves through campus events and organizations. On MonsterTrak, the largest student job and internship site, you can target your posting to the schools you want to recruit from; the site charges $30 per posting per school, with a discount for multiple postings. Wherever your job posting appears, get it in as early as possible; students typically start thinking about summer internships at the end of the fall term. And remember: Interns are cheap, but they’re not free. Generally, if you’re paying someone, you have to pay minimum wage; for unpaid internships, certain educational criteria often must be met. Check with your state’s labor department for the regulations in your area. Free Consulting Score, the Service Corps of Retired Executives, is a nonprofit partner of the U.S. Small Business Administration that provides free online counseling on everything from accounting to workflow analysis, provided by a volunteer corps of working and retired business owners and executives. Score also offers free one-on-one and team business counseling at 389 locations around the country; find the one closest to you at score.org. Copy, Right Mid-level business copiers can cost $5,000 and up. Because of the high entry cost, and the near certainty that the “latest technology” will be outdated in a year (if not six months), leasing–which often includes an option to upgrade and can cost as little as $50 a month–is usually more attractive. When signing a lease, make sure to clarify the service and repairs included, and what the response time will be. Beware of contracts that require a minimum or maximum monthly number of copies; work out pay-as-you-go terms instead. And remember, you don’t have to buy paper and toner from your copier supplier–you can usually save money by buying these from an office-supply source. And if you don’t expect to make more than 700 copies a month, you probably don’t need a “business” copier at all–you can get by with a combination printer-copier that costs a few hundred bucks. Ink & Toner Deals abound on generic, remanufactured, and even name-brand cartridges. There are numerous online office supply and ink specialty stores–InkSell.com, 4inkjets, Databazaar.com, and InkjetSuperstore.com–that often have better prices than the superstores and printer manufacturers. For example, in a recent search on comparison site NexTag, we found an HP Laserjet 2400 cartridge for $120; the same product retails for $206 at Office Depot. If you’re willing to use refurbished cartridges, you can pay as little as $70. Meanwhile, OfficeMax recently launched a nationwide refill program for inkjet cartridges, which could translate into cost savings of up to 50 percent. Best for Blogging WordPress.org provides a free, easy-to-use tool for adding an easy-to-update blog to your company’s existing website. If you want to go cheap–and skip a formal website altogether–blogger.com (owned by Google) and wordpress.com (not wordpress.org) will host your blog for free. The only drawback: The generic domain name (blogspot.com or wordpress.com) can look unprofessional. Office Furniture Check out dealer show rooms and keep tabs on any floor models you like. Come June, when NeoCon, the huge convention of office furniture manufacturers, takes place, dealers want to get new stuff on the floor–which can translate into good deals on old merchandise. Discounts of 20 percent or more are not uncommon. For general office furniture, check the lower-cost subsidiaries of the big manufacturers, such as Steelcase’s Turnstone line. And don’t forget eBay, where bargains on durable workplace basics abound. Here are some recent examples: 34 Steelcase telemarketing cubicles: $6,700; eight Herman Miller workstations: $3,995; 12 Steelcase office desks: $1,500. Paper, envelopes, pencils, staples and the rest Rather than buying different items from different vendors, consolidate your office-supplies shopping in one place. The big office superstores all offer online order management, free delivery for orders over $50, and loyalty rewards programs. In addition, OfficeMax Commercial Solutions and Staples Business Advantage are free programs that work like managed-travel programs, helping customers track and reduce total office-supply spending through more efficient ordering and discounts for volume buying. Office Depot offers similar services through its Business Services Division. Negotiating an Iron-Clad Shipping Contract The major package delivery companies–FedEx, UPS, DHL–are all competing for the small-business market. It’s up to you to meet with their reps and determine what services you need, which company best meets those needs, and which one offers the best deal. Beware of add-on charges for things like sending packages to nonurban areas and shipping fragile items; shippers today have more than 100 such charges, compared with about 30 five years ago. Many of these fees are negotiable, though it helps if you have what the shippers call “good shipping characteristics”–high volume, packages that tend to fall in the same size category (say, more than 100 pounds), and lots of deliveries to urban Zip codes (which are less expensive to deliver). Smart negotiating can shave 10 to 20 percent off your shipping bill, says Mike Erickson, president and CEO of AFMS, a consulting firm that specializes in evaluating and negotiating business shipping contracts. Indeed, if you do a lot of shipping, it makes sense to hire a consultant, as shipping contracts are often difficult for laypeople to decipher. A company car–plus a tax break Under the Energy Policy Act of 2005, individuals and businesses that buy or lease a new hybrid gas-electric car or truck, or an alternative-fuel or fuel-cell vehicle, are eligible for an income-tax credit of up to $3,400, depending on the fuel economy and the weight of the vehicle. (This credit is in addition to the regular depreciation or lease expense you’re allowed to deduct for any vehicle.) If you buy more than one vehicle, you get a tax credit for each. This tax credit applies to vehicles “placed in service” beginning January 1, 2006. Once a manufacturer has sold 60,000 eligible vehicles, the tax credit for its cars will be reduced, and eventually eliminated. So get on it now. When buying a printer, check out the “print yield” A cheap inkjet may be easy on the wallet today, but it’ll end up costing you more later. That’s because with printers, it’s all about consumables–paper, toner, etc. For example, with a $300 laser printer and compatible cartridge, it costs $30 to print 1,000 pages (black ink only); with an $80 inkjet printer from the same manufacturer, the same print run costs $100. After a little more than 3,000 pages, the more expensive printer has paid for itself. Check out the “print yield” specs for the toner cartridges the printer requires, and divide the price by that number–that’s your cost per page. Let that number, not the cost of the printer, guide you to the real bargains. Retail Space Mall tenants may enjoy foot traffic, but that traffic comes with a steep price tag–incidental costs can run from $18 to $55 per square foot per year. Wherever you set up shop, scrutinize your lease for so-called pass-throughs–charges on top of the basic rent for things like common-area maintenance–and make sure you’re paying a share that’s proportionate to the actual square footage you’re occupying. Another way to save: Minimize your square footage in an expensive retail area by leasing storage space in a cheaper space off the premises. Stress-Free Employees Treating your staff to monthly massages may seem like a needless indulgence, but it can save you in the long run. Research shows that employees are more productive on quantitative tasks after massages and report feeling less stress. There is also, not surprisingly, less absenteeism on days that massages are scheduled. And because office massage specialists provide education about ergonomics and repetitive-stress injuries, you may reduce the costs of such injuries. A 15-minute seated massage–about the time of a coffee break–is all it takes to realize the benefits. On-site massage rates vary by location–expect hourly rates of about $75 and up in larger cities (a massage therapist will typically fit in three 15-minute massages per hour). Go to amtamassage.org and use the locator service to find a qualified provider in your area. Corporate jet: a good option for small groups It’s a bit of a stretch to call a company jet a bargain, but look at the upside. There’s no penalty for booking last minute, so it’s attractive if you make spur-of-the-moment trips. And since jet operators charge by the hour, not per person, a private flight can be a good option for flying small groups (midsize jets can accommodate about eight). Full or fractional ownership requires laying out millions up front, but Sentient and Blue Star Jets‘ SkyCard program offer membership plans that give you planes on demand for less than the cost of fractional or outright ownership. With both companies, you make an initial deposit (minimum $100,000 for Sentient, $50,000 for Blue Star) and funds are deducted as you use flight time (hourly fees start at about $2,000). Deals on PCs Comparison shopping is a no-brainer. But with PCs, you’ll be surprised at how large the price variations are for identical products. A recent search on comparison-shopping site NexTag, for example, turned up about 20 different vendors offering new Toshiba Portege R200 laptops for prices ranging from $1,162 to $2,159. Another useful tool is NexTag’s “Price Drops” section, which tracks the market in a range of tech categories and reveals, for example, that in April, the best price for an IBM Thinkpad T43P abruptly dropped 25 percent. Travel Tips Travel is typically a company’s second or third largest controllable expense, and one way to control it is to implement a managed-travel program. Most of the online booking services have launched programs for small companies. Expedia Corporate Travel ($149 a year) and Orbitz for Business (fees vary according to use) drive down travel expenses by 10 percent or more by lowering transaction fees (an average of $5 per ticket, compared with about $30 for traditional agencies) and negotiating discounted rates with airlines, hotels, and rental car companies. Obviously, the larger the company, the larger the discount a travel service can negotiate. But in some markets, just being able to offer an airline or hotel a 10 percent incremental increase in your company’s business can be a potent bargaining tool. American Express’ small-business travel program (starts at $500 a year; $100 for small-business cardholders) offers discounts on airfares of up to 15 percent on domestic flights and 35 percent on international trips. AmEx also promises to beat any fare you find online. Website Hosting and Design Some broadband providers offer free hosting with their service. If yours doesn’t, consider one of these low-cost options, all of which include easy-to-use design and e-commerce tools and templates to get your site up and running quickly. Yahoo Hosting and domain registration: $12 per month and up E-commerce: $40 to $300 per month, depending on sales volume Homestead Hosting and domain registration: $20 to $50 per month (plus $20 setup fee) E-commerce: $7 to $60 per month Microsoft Office Live Hosting and domain registration: Basic service is free; added features cost $30 a month Web Traffic Analysis Google Analytics is a free and useful Web analytics tool–if you can get it. Right now there’s a waiting list that doesn’t seem to be budging. Fortunately, Google is far from your only affordable option. Check out ClickTracks‘ Analyzer, a basic hosted service that charges $49 per month (or buy the software for $495); Web analytics program SmarterStats 3.0, free for use on a single website (available at download.com); StatCounter, free for up to 250,000 page views; and Site Meter, which starts at $9.95 per month. Numerous free trial versions of other programs are available, too–which can at least hold you over if you decide to wait for your Google spot to open up. Industrial Space Even in the information age, manufactured goods can’t telecommute. That’s why industrial space–factories, warehouses, distribution centers–always costs more the closer it is to large population and transportation centers. Prices decline the farther out you move, but then transportation costs go up–so what appears to be a bargain often is not. The right balance is easiest to strike in less pricey “second-tier” cities such as Columbus, Indianapolis, and Louisville, as well as on the fringes of primary markets–places such as eastern Pennsylvania, lower New York state, and northern Los Angeles County. Aeron Chairs Go to authorized Herman Miller dealers first and think of the advertised price as a starting point. Even if you’re buying just 10 or 20 chairs, you can bargain. “Every contract is individually negotiated,” says Herman Miller spokesman Bruce Buursma. Dealers often have used chairs coming back from leases, which can cost 20 percent less than new ones. Consider lower-cost models too–Herman Miller’s basic Celle chair, for example, offers Aeron-like features for about $499, compared with $699 for a basic Aeron. If you’re not making progress with the brick-and-mortar dealers, go online. Here’s what a recent price comparison turned up (all prices include shipping): New Aeron Chair $699 at officedesigns.com, ultimatebackstore.com, sit4less.com, homeofficesolutions.com (volume pricing available) “Like New” Aeron Chair (floor models or returns) $519 at luxurychair.com, $560 at trendychair.com, $539 at sit4less.com’s clearance section Aeron Look-alikes Sit4Less “E” Chair, $399 at sit4less.com Ergonomic eChair, $319 at luxurychair.com Mesh eChair, $269 at designerseating.com A serious coffeemaker–and serious coffee If you consider a super automatic espresso machine to be a super productivity booster, check out the “outlet” section of wholelattelove.com, which sells manufacturer-refurbished machines at deep discounts–a Jura-Capresso Impresa S9 (list price, $2,400) goes for $1,399, shipping included. As for beans, get the gourmet stuff from old-school coffee roaster D’Amico Foods, which ships nationwide from its store in Brooklyn–at great prices ($6 a pound for the house blend espresso). The best rate on credit cards Start by checking out what your bank offers, then do some comparison shopping. As with personal credit cards, there are numerous no-annual-fee cards out there, so avoid paying such charges unless you truly require the particular services or reward-program benefits of a certain card. At sites like CreditCardGuide.com, CreditCards.com, and MyRatePlan.com (go to the credit card section), you can compare cards and apply online. Fun and Games Nothing succeeds in conjuring that giddy dot-com mood quite like little plastic soccer players. A new Striker foosball table retails for $699. But you almost always can find better deals at online specialty stores, many of which also include free shipping–which is no small matter, since delivery of a foosball table can cost a couple hundred bucks. Here’s a sampling of some of the best deals on office amusements: Foosball Table Striker foosball table $499, shipping included, at justfoosballtables.com      Air Hockey Carrom Premium Hydralumina With Scoring, six-foot model $540, shipping included, at christophersgames.com    Ping-Pong Table Prince Competitor table tennis table $359, shipping included, at dickssportinggoods.com Pool Table Charleston eight-foot table $1,787, crating and air freight included, at pooltables-direct.com    Pinball/Arcade Simpsons game $4,800, with shipping, christophersgames.com 1979 Space Invaders cocktail table arcade game $700 (plus $350 shipping), recently listed on eBay     Turn Your Office Into an Art Gallery Why buy pricey art for your office walls when you can rent? A number of major art museums have rental programs–and many will even help you choose the best pieces for your space. The Artists Gallery at San Francisco’s Museum of Modern Art charges about $350 to rent a $5,000 painting for three months; a $1,000 painting rents for $170. Like most museum rental programs, SFMOMA’s program focuses on local talent and has thousands of work in all media; photography tends to be the least expensive option. Other museums with rental programs include Los Angeles County Museum of Art, Portland Museum of Art, the Seattle Art Museum, and the Racine Art Museum in Racine, Wisconsin. Local galleries may also rent to businesses.    The Office of Your Dreams Right now, the cheapest downtown Class A rents in major markets can be found in Atlanta, Dallas, Denver, and Seattle–places where $20 per square foot can land you palatial digs that would cost three times as much in New York City. Wherever you live, make sure you keep up with local business news. When companies close, downsize, or move out of town, they’re often left with time on their existing leases. “Subleasing is where a smaller business can really pick up a bargain,” says Andrew Abramson, a senior vice president with Grubb & Ellis in Washington, D.C. Abramson points out that in addition to lower rent, expensive improvements that were made by the previous tenant–such as phone systems and furniture–are often thrown into the deal as an incentive. Meantime, if you forgo a view and instead take lower-floor or obstructed-view space, you can save anywhere from 10 to 30 percent on rent. (Go to grubb-ellis.com/research to check pricing in markets throughout North America.) Location, Location, Location How much do real estate prices fluctuate nationwide? To find out, we searched for Class A office space in three major markets–Denver, Atlanta, and San Francisco. In each city, we found a plush office of about 6,000 square feet (enough for about 20 people) in a fancy, downtown building with all the amenities-health club, concierge services, covered parking, etc. The annual lease rates, of course, were all over the map. San Francisco $37 per square foot Denver $25 per square foot Atlanta $29 per square foot The Wall Street Journal A staple of office waiting rooms everywhere, the Journal does not offer corporate discounts for bulk orders to new subscribers. Check for special offers on the comparison-shopping sites as well as newspaper specialists subscription-offers.com and discountednewspapers.com. And check the paper’s website, too. At the time of writing, an offer for new subscribers made dealing directly with the publisher the cheapest option out there by far (56 weeks for $99); only one third-party distributor was able to beat the regular yearly subscription price of $215. (Note: This special offer was available online only; operators at the Journal‘s 800 number did not mention or even acknowledge this option.) The Clean-Up Crew Any cleaning service you hire should be bonded and insured–if cleaners mess up your stuff, or themselves, you don’t want to get stuck with the bill. Prices for that will be higher than for under-the-table help, but worth it. Remember, cleaning people often work when the office is empty; you need to be able to trust them. Make sure the company does background checks on workers, and check multiple references. Old-school long-distance service Negotiate directly with carriers or go through resellers, or CLECs (competitive local exchange carriers), which tend to price more aggressively and be more focused on the needs of smaller businesses than the large telecoms. There are many sites that let you solicit bids and compare rates, including PhoneSaver.com and BuyerZone. As you compare services, look for one that will bill the shortest time increments possible for long-distance–one- to six-second intervals, rather than 30-second ones. The smaller increments can translate into savings of 10 percent or so. International calling It’s not a substitute for a traditional phone system, but Skype, which lets you make calls directly from your computer, is a useful supplement if international calls are a big part of your phone bill. The quality usually can’t match a good phone connection, but the prices can’t be beat. Calls to other Skype users (through your computer) are free wherever you’re calling from, and calls to landlines and cell phones in the U.S., much of Europe, China, and Japan cost about two cents per minute. Broadband: Why You Need a Broker Unless you have a strong preference for a particular provider, you’ll generally get better rates through a broker–brokers do the comparison shopping for you, and because they buy in bulk, tend to have greater negotiating leverage. Typically, there is no charge to the consumer in working with a broker; instead, the providers pay the brokers a fee. Look for resellers that have been in business at least a few years, and make sure they show you quotes from several providers. Broadband is an extremely competitive market, so avoid getting locked into a long-term contract. Most companies require a two-year minimum commitment–don’t sign up for a longer term. You can solicit quotes from multiple vendors and resellers at comparison-shopping sites. Office Design Most professional designers charge between $75 and $200 an hour. But hiring one can actually wind up saving you money. Designers often see possibilities that you do not. A designer might suggest ways to use inexpensive materials and built-ins–using melamine boards in place of desks, for example–that can help reduce the amount of office furniture you need to buy. And when you do buy, designers get discounts of as much as 50 percent. The trick is to keep your designer on a short leash by defining the task at hand as narrowly as possible. To find a designer, go to asid.org, the website of the American Society of Interior Designers, and click on the “Find a Designer” link. Before You Buy Thanks to the Web, comparison shopping is a cinch. Sites such as Bizrate.com, PriceGrabber.com, Shopping.com, and NexTag.com may turn up the deal you’re looking for on any number of items. The following sites may be helpful for specialized searches. Broadband service Broadband.com Broadbandbroker.com Buyerzone.com EverythingT1.com Business equipment leasing Buyerzone.com Commercial real estate Equityoffice.com Cushwake.com (click on “Property Listings”) Grubb-ellis.com (click on “Properties”) Computers/software Shopper-zdnet.com Shopper.cnet.com Credit cards Creditcards.com Creditcardguide.com Myrateplan.com Newspaper subscriptions Subscription-offers.com Discountednewspapers.com Phone plans and systems Phonesaver.com Buyerzone.com

He Took On the Whole Power-Tool Industry

In February 2001, Stephen Gass strode to the podium in a conference room at Caesars Palace in Las Vegas and began the video presentation for SawStop, his new invention. The 75 attendees watched the screen closely as a woodworker fed a sheet of plywood into a power-saw blade spinning at 4,000 rpm. Then a hot dog was placed in the path of the blade. Miraculously, the instant the blade made contact with the wiener, the saw shut down and the blade retracted. The dog escaped with only a small nick — substitute a finger and it’s the difference between a cut and an amputation. Gass had given the same dog-and-pony show a dozen times, mostly for woodworkers, contractors, and a few industry executives. But this audience was different. It consisted of lawyers for the Defense Research Industry, a trade group for attorneys representing the power-tool industry. SawStop could help prevent thousands of serious injuries caused by power tools each year, Gass believed — if the industry would license it. He returned to his seat thinking he had made his case. Then Dan Lanier, national coordinating counsel for Black & Decker, stepped to the podium. His topic: “Evidentiary Issues Relating to SawStop Technology for Power Saws.” Lanier spent the next 30 minutes discussing a hypothetical lawsuit — in which a plaintiff suing a power-saw manufacturer contended the saw was defective because it did not incorporate SawStop’s technology — and suggesting ways defense counsel might respond. Lanier recalls it as a rather dry exploration of legal issues. Gass heard something different. To his ears, Lanier’s message was this: If we all stick together and don’t license this product, the industry can argue that everybody rejected it so it obviously wasn’t viable, thereby limiting any legal liability the industry might face as a result of the new technology. (Lanier denies this was his point.) Gass was stunned. His tiny start-up, run by three guys out of a barn in Wilsonville, Oreg., had captured the attention of the entire power-tool industry. For months, he had been negotiating with major players such as Ryobi, Delta, Black & Decker, Emerson, and Craftsman about licensing his invention. Instead, they seemed intent on trying to make him and his product go away. Some 32,000 Americans are rushed to emergency rooms with table-saw-related injuries each year, according to the Consumer Product Safety Commission; more than 3,000 of those visits result in amputations, usually of fingers or hands. The medical bill to reattach a severed finger runs from about $10,000 for a clean wound to more than $25,000 if there’s nerve damage, infection, or other complications, according to James W. Greer, president of the Association of Property and Casualty Claims Professionals, a trade group in Tampa. Factor in rehabilitation and lost time at work, and the cost per injury can easily reach six figures. Indeed, in 2002, the CPSC estimated the annual economic cost of table-saw injuries to be $2 billion. That’s more than 10 times the size of the entire $175 million table-saw market. Clearly, this is an industry that could use a better mousetrap. That’s what Gass figured he had in the summer of 2000, when SawStop’s technology made its debut. A year later, the Consumer Products Safety Commission awarded the device its Chairman’s Commendation for product safety. Popular Science magazine named it one of 100 Best New Innovations. Tool industry bigwigs seemed impressed too. “It is probably one of the most major developments in the area of product safety applicable for table saws,” said Peter Domeny, director of product safety for S-B Power Tool, which makes Skil and Bosch tools. So, four years later, why isn’t SawStop on every table saw on the market? That’s the funny thing about better mousetraps. Build one, and the other mousetrap makers will probably hate your guts. They might even try to squeeze you out of the mousetrap business altogether. Just ask the inventors of air bags, safer cigarette lighters, and automatic shutoffs for electrical appliances — all of which encountered resistance from the status quo. Ultimately they prevailed and their innovations became standard. Gass still has a long way to go. Gass didn’t set out to take on the power-tool industry. Nor did he ever see himself as an entrepreneur. The amateur woodworker was standing in his workshop one day in 1999, staring at his idle table saw. “The idea came to me that it might be possible to stop the blade quickly enough to avoid serious injury,” he says. A patent attorney who also holds a doctorate in physics, Gass loves nothing more than solving complex technical problems. He got out pencil, paper, and calculator and got to work. Stopping the blade, he figured, would require a two-part process. First, he needed a brake that would work quickly enough when it came into contact with a woodworker’s hand. Next, he had to design a triggering system that could differentiate between finger and wood. Given the speed of the blade, it would have to stop in about 1/100 of a second — or at about an eighth of an inch of rotation after making contact. Any further, and the cut would be so deep that the device would be useless. To stop the blade this quickly would require about 1,000 pounds of force to decelerate the blade in 10 milliseconds. That calculation took Gass about 30 minutes. The trigger problem was a little more complicated, but Gass came up with the idea of running a small electrical charge through the blade. The system would sense when the blade hit flesh because the body would absorb some of the charge. The resulting drop in voltage would be enough to trigger the brake and stop the blade almost instantly. Gass spent two weeks designing the technology and, using a $200 secondhand table saw, an additional week building a prototype. Then he began to experiment. With the blade whirring, he touched his hand to its smooth side. It stopped immediately. The same thing happened when he ran a hot dog into the blade’s teeth. Gass repeated the experiment dozens of times — and each time the blade stopped immediately. Convinced his invention would be embraced by the industry, he videotaped a demonstration, registered the patent, and set out to convince manufacturers to license the technology, which he had dubbed SawStop. He sent a video demo to Delta Machinery in Jackson, Tenn., one of the largest table-saw manufacturers, and waited. Gass was pleased with his results, but he also knew there was something else to be done: He had to test SawStop on a real finger. “There’s not a lot of demand for a saw that’s safe for hot dogs,” he says with a laugh. And so, on a spring afternoon in 2000, Gass stood in his workshop and tried to summon the moxie to stick his left ring finger into the teeth of a whirring saw blade. He had rubbed the digit with Novocain cream, hoping to dull the pain of the cut. On the first try, his heart beating furiously, he eased in close but recoiled before making contact. A few minutes later, he tried again. This time, he rolled his finger close enough to get a faint red mark, but panicked and pulled back before the brake triggered. By now, his forearm was cramping from the tension. It was difficult to keep his hand steady. Still, on his third attempt, he kept his nerve — and the blade stopped, just as he knew it would. “It hurt like the dickens and bled a lot,” he says. But the finger remained intact. Several months later, Gass finally heard back from Delta. “No, thanks. Safety doesn’t sell,” he says he was told over the phone. (Delta, now known as Delta Porter Cable, is now owned by Black & Decker. A Delta spokesperson who asked not to be identified denies that a Delta employee made the comment.) Gass could not believe his ears. “Everybody in woodworking knows somebody who’s lost a finger or had an accident,” he says. How could a major manufacturer not be interested? “These guys would walk up to us and say, ‘I wanna shake your hand.’ A lot of them were shaking with two or three fingers missing.” Gass refused to give up. Working with three other lawyers from his Portland law firm, David Fanning, David Fulmer, and David D’asenzo, he raised $150,000, built a more sophisticated prototype, and signed up for the International Woodworking Fair in August 2000 in Atlanta. The reaction there was phenomenal. SawStop’s booth was packed with spectators who stood riveted as Gass and his partners fed wiener after wiener into the table saw. “Afterward, these guys would walk up to us and say, ‘I wanna shake your hand for doing this,” recalls Fanning. “A lot of them were shaking with two or three fingers missing.” It was all the validation the four men needed. A month later, Gass and Fanning walked away from law partnerships to pursue SawStop full-time. Fulmer, an associate at the firm, followed a few months later. D’asenzo invested in the venture but kept his day job. The fall of 2000 was hardly an auspicious time to launch a start-up. The Internet boom had just gone bust, the Nasdaq was in free fall, and investors were gun-shy. Yet SawStop was so practical and easy to understand, the trio had little trouble raising $1.2 million in angel funding from several different investors. They invested in more R&D, better prototypes, and small salaries for the three principals. “It was a no-brainer,” says Grant Simmons, a New Orleans urologist who invested an undisclosed amount in SawStop after reading about the company and seeing a video demonstration in 2004. It was Simmons’s first experience as an angel investor, and his interest was more than just financial: His father was a lifelong woodworker who had lost a finger in a table-saw accident. “This is revolutionary,” Simmons says. “They are applying basic physics in a practical way to address a very important issue that people in the industry have totally ignored — safety.” Gass, Fanning, and Fulmer, meanwhile, filed more than 50 patent applications to protect their invention. The only thing they lacked was industry cooperation — but that seemed inevitable. After all, they believed, common sense and consumer demand ultimately would win out. What’s more, the technology had implications far beyond table saws. It could potentially boost the safety of all power saws, including band saws and circular saws, as well as nail guns, lawn mowers, and other products. For the next two years, the partners engaged in what seemed to be promising talks with high-level executives at Emerson, Black & Decker, and Ryobi. In January 2002, they appeared to have turned the corner when Ryobi agreed to license SawStop’s technology. Under the terms of the deal, there would be no up-front fee; Ryobi would pay a 3% royalty based on the wholesale price of all saws sold with SawStop’s technology. The number would increase to 8% if the majority of the industry also licensed the technology. It was not a get-rich-quick deal, but Gass believed it was a vital first step. When the contract arrived, Gass noticed a typo and called Ryobi’s attorney, Bob Bugos, to make the correction. Gass says Bugos apologized and promised to take care of it right away. (Ryobi representatives declined to comment for this story.) When a week passed and the revised contract still had not arrived, Gass called back. He says Bugos was very apologetic and assured him the contract was on its way. Again, it didn’t come. Gass says he called every two weeks and each time Bugos made the same promise. After about six months of going back and forth, it finally dawned on Gass that the Ryobi deal, like all the others, was going nowhere. Indeed, the major power-tool manufacturers have professed to be somewhat less than impressed with SawStop. “The device has not been field-tested for results, durability, and reliability,” said a representative from Delta Porter Cable. “It’s an experimental system, not yet field-proven.” According to Dan Lanier, the Defense Research Industry attorney, all of the manufacturers approached by Gass independently tested and evaluated the technology. And each one, Lanier said in an e-mail, encountered “sign injury even when it works, Gass asks the following question: Isn’t it better to walk away with a cut, even a deep one, than to lose a finger or a hand? “I think they were looking for reasons not to implement it,” he says. Gass sees the objections as a smoke screen for the industry’s real concern: the increased risk of product-liability litigation. In most cases, when people sue power-tool manufacturers because they’ve lost a finger or hand in an accident, they’re unsuccessful — because it’s tough to prove that the manufacturer did anything wrong. Add SawStop to the mix, however, and the picture changes. Suddenly, the industry is promising an injury-proof saw. What if someone got hurt? “The manufacturer would be at a deeper risk and more vulnerable because it had made a promise of what the technology could do,” says Jim O’Reilley, a product-liability expert at the University of Cincinnati. “Companies are going to be reluctant to expose themselves to that higher risk.” Indeed, precisely who would assume that risk turned out to be a major sticking point in SawStop’s licensing negotiations. The manufacturers believed Gass should indemnify them against any lawsuit if SawStop malfunctioned. Gass, however, says that he could not possibly make such a guarantee since he would not actually be manufacturing the saws. And there is another facet to the liability issue. If SawStop did come to market and was proved effective in preventing accidents, it might be easier for plaintiffs to win lawsuits against manufacturers of traditional saws, because juries might be more likely to return a verdict against a manufacturer that chose not to implement SawStop. That’s the main reason, Gass believes, that the big tool makers are refusing to deal with him. They want his product to go away. After the deal with Ryobi fell apart in mid-2002, Gass, Fanning, and Fulmer faced a tough choice: Abandon the company and return to practicing law or build the saws themselves. None of the men had ever run a company, but they all understood that it’s one thing to be an inventor and another to be an entrepreneur. They would be responsible for designing, manufacturing, marketing, and sales along with the day-to-day operations of a business. It was a tough prospect — but not a tough decision. All three agreed that if they didn’t act, their technology would never see the light of day. “It seemed like the right thing to do,” says Fanning. “There aren’t very many opportunities to make money and do something good.” With wives and kids to support, Gass and his partners have found that the decision has not always been easy to stand by. Gass fondly recalls the six-figure salary he earned as a patent lawyer. At one point, he was so close to returning to his legal career that he got quotes for renewing the legal-malpractice insurance policy he dropped when he devoted himself to SawStop. “I never doubted my invention or wanted to give up, but I’ve wondered if we would be able to keep going,” he says. “It’s been touch-and-go several times with money, and we always manage to pull through at the last minute.” SawStop now operates with eight people out of a two-story barn Gass built himself. Filled with electronics, high-tech machinery, and every tool imaginable, the first floor is a handyman’s paradise. In the corner is a large stack of woodworking timber left untouched since Gass launched his venture. Gass logs 12- to 14-hour days running the business upstairs. Desks, computers, and filing cabinets fill the second-floor office space. A map of the United States hangs above the conference table. It’s dotted with colored pushpins, each one representing a city where someone has purchased a SawStop table saw. The first one rolled off the assembly line of a Taiwanese manufacturing plant in November 2004. SawStop has since sold about 600 and has 300 more on back order. A basic contractor saw retails for $799; the professional-level cabinet saw goes for $2,500. The company relies on trade shows, news stories, word of mouth, and ads in woodworking magazines for marketing. Selling online and direct-to-consumer is an acceptable way to get started, but Gass knows that to reach the larger market he will need to get into home improvement stores, where competition for shelf space is fierce. He’s had discussions with Home Depot and Lowe’s, but neither has committed to carrying the product. “Accidents are usually caused by human error, but this saw grants you forgiveness,” says one contractor. So for now, Gass is banking on people like Sharon and Don Biers, owners of Collins Custom Cabinets. After one of the employees at their Lowell, Ark., shop lost a finger in a power-saw accident in February, the Biers bought a $2,500 SawStop cabinet saw and have since ordered two more. It didn’t take long for the purchase to pay off. Within two weeks, another employee, John Stroud, inadvertently shifted his hand into the path of the blade and the saw shut down when it hit his fingernail. “We made the calculation that it’s worth it for the safety of our guys,” says Sharon Biers. “The accidents are usually caused by human error, but this saw grants you forgiveness.” And not just for professionals. In May, Gass received an e-mail from a high school shop teacher in Princeton, Wis. “I have a sophomore who still has two thumbs thanks to your saw,” the man wrote. The company knows of at least five other amputations that have been averted. With the big tool companies declining to participate, SawStop is seeking other ways to make sure its technology is adopted. In April 2003, the company filed a petition with the Consumer Product Safety Commission to make SawStop-like technology standard on all table saws. Six months later, the Power Tool Institute, a consortium of 17 power-tool makers, filed an opposing brief in which it argued that SawStop is a “speculative and untested technology. In addition, the cost to consumers and manufacturers of granting the petition would far outweigh any benefits that may be realized.” The industry also claims to be developing its own safety systems. The CPSC is expected to release its findings this summer. If it states, as Gass hopes and expects, that the technology is effective, it will be the first step in a long process of making SawStop — or a similar injury-prevention system — mandatory. Meanwhile, the industry’s product-liability fears appear to be coming to life. In 2003, a construction worker walked into the Wellesley, Mass., office of attorney Richard J. Sullivan. He was looking for someone to represent him in a case against Chicago-based S-B Power Tool. The worker had lost his thumb and four fingers while using a table saw. Doctors were able to reattach them, but even after six surgeries and $150,000 in medical bills, he still had no real functionality in the hand. Living on workers’ comp, he fell behind financially and was forced to sell his home. Sullivan turned the case down twice because he didn’t see a way to hold the manufacturer accountable. Then a colleague told him about SawStop. “His injury occurred on a saw manufactured in April 2003 and sold in May 2003,” Sullivan says. “The industry has known about this technology since 2001. That gave the manufacturer plenty of time to react.” The lawsuit, filed in Massachusetts state court in the summer of 2004, alleges that the manufacturer was negligent for not implementing the technology and seeks compensation for lost wages, future lost wages, and pain and suffering. (Attorneys for S-B Power Tool responded in January, denying all claims.) “If Gass can figure this out by tinkering around in his backyard, what has this industry been doing for the past 20 years?” asks Sullivan, who has since taken on five similar cases. “They’re like the auto industry, which had to be dragged kicking and screaming to install air bags.” Gass believes that Sullivan’s cases are only the tip of the iceberg. “The legal standard says you have to make a product as safe as you reasonably can, and if you fail to do that, you’re going to be responsible,” he says. While Gass wants SawStop to be successful financially, he also admits that what began as an interesting physics problem in his workshop has become something of a crusade. “This is important to society and that responsibility weighs on me,” he says. “It would have been so much easier if the manufacturers had just licensed this. Then, having SawStop would be just like having a stereo with Dolby or running shorts with Gore-Tex.” Indeed, Gass still dreams of getting out of manufacturing altogether. He really doesn’t want to make the power tools we buy. He just wants to make the power tools we buy better. Melba Newsome is a freelance writer in Charlotte, N.C.

Nailing It

They needed it overnight. They wanted the best. In the race to build the first online hardware store, Peter Hunt and Rich Takata put their company in the hands of outright strangers The Company Name: CornerHardware.com Inc. Founded: Incorporated May 1999; Web site launched early 2000 Location: San Francisco Cofounders: Chairman and CEO Richard Takata; president and chief operating officer Peter A. Hunt Employees: 35 full-timers Mission: Creating an online home-improvement store, magazine, and community for do-it-yourselfers URL: www.cornerhardware.com The Developer Name: Xuma Founded: 1998 Location: San Francisco; with offices in New York, Los Angeles, and Las Vegas Cofounders: CEO Joe Cha; chief technology officer Jamie Lerner Employees: 250 Mission: Producing built-to-order Web sites for E-businesses URL: www.xuma.com In December 1998, Peter Hunt set out to tackle what should have been a simple, joyous task: building a tree house for his four-year-old son for Christmas. Hunt couldn’t wait to start the project. It wasn’t just that he welcomed the diversion from his high-powered job as an investment banker. It was more that, ever since he’d been a kid, Hunt had loved working with his hands: making model trains and airplanes, building furniture, fixing things around the house. As an adult he’d dreamed of buying a corner hardware store in some rural New England town, the kind of place with a bell over the door and shelves lined with hinges and screws and doorknobs, where he’d spend his days happily helping customers pick out the right paintbrush or handsaw. But with two kids and a top job at Montgomery Securities in San Francisco, the lanky, thoughtful Hunt didn’t even have time to stop into a local hardware shop, let alone wander through a giant home-improvement warehouse. He assumed he’d save time by buying everything he needed for the tree house — instructions, lumber, materials, and tools — online. So he went to the Web and looked for hardware sites. And looked. And looked. He found nothing except a loose network of like-minded tree-house enthusiasts, many similarly frustrated by their own fruitless online searches for supplies and information. From that experience, Peter Hunt, banker, suddenly figured out how to finally become Peter Hunt, hardware guy. Hunt’s thinking went like this: What if there were lots of little communities out there — tree-house builders and woodworkers and plumbers and fixer-uppers and even contractors — all hungry for online hardware and home-improvement advice? And what if somebody could provide it for them in one friendly, convenient location, sort of a virtual corner hardware store? In early 1999, Hunt, then 35, took a week off to write a business plan for just such a company. But he knew something was missing. He needed a business partner — a veteran hardware retailer, a real insider. When he asked around, he kept hearing the same name: Rich Takata. Richard T. Takata, then of Seattle, had been in the hardware business for 24 years. Takata, who’d most recently been president and CEO of Eagle Hardware & Garden Inc., had remained with the 41-store chain after North Carolina­based Lowe’s Cos. had bought it for $1.4 billion. (In fact, Hunt’s firm had handled the sale.) Although reserved and soft-spoken, Takata, then 49, was hardly averse to risk; in his spare time he occasionally drove race cars. A lifelong do-it-yourselfer, Takata also knew his industry and its customers. Over the years he’d waited on thousands of people, even during store visits when he was the company’s CEO. And like Hunt, whose own company had been acquired by North Carolina­based NationsBank, Takata was ready for a change. Xuma’s founders named their Web-development company after an ancient Chinese battle cry. In April 1999, at the urging of a mutual friend, Hunt and Takata met for dinner to talk about launching a big home-improvement E-commerce site. They discovered they had much in common. Both were quietly intense, articulate, committed. Both were customer-service evangelists, true believers in keeping promises and building long, loyal relationships. Both believed passionately in the Internet’s potential for business. And both had high — some might say almost impossible — standards for themselves, their companies, and those who worked for or with them. Of the two, Takata was more tactical and analytical, a manager with a keen recall of industry statistics and an almost instinctive understanding of business trends. Hunt, very much the money guy and deal maker, was also more sentimental. (He documents CornerHardware.com’s growth in a scrapbook filled with mementos like copies of the company’s incorporation papers and of its early bank deposits, and Polaroid photos of each newly hired employee.) From the start, the two men agreed they wanted to do more than lead the Web in sales of drill bits and deck stain. They wanted to re-create the old-fashioned corner hardware store of Hunt’s dreams and Takata’s experience: a place with well-stocked shelves, knowledgeable clerks, lots of how-to information, and most of all, a friendly, collegial, yes-you-can-do-it-yourself atmosphere. It would, of course, be called CornerHardware.com. They knew it was a big idea with hefty potential; pulling in even a small fraction of the $400-billion-a-year home-improvement business would yield a fortune. They were amazed that nobody had launched the kind of venture they envisioned, and they knew that before long somebody else certainly would. What they wanted to do — build a full-service online hardware store and community — would cost at least $2.5 million. Takata and Hunt knew they needed to move fast — and they did. Within three weeks of their first meeting, both men had quit their jobs; put up $250,000 each of their own money; raised about $500,000 more from angel investors, family, friends, and colleagues; and incorporated their business. But for all the partners knew they needed to do, there was still plenty they needed to learn. Chief among the lessons: just how tough it would be to build a big Web business in a matter of months — and how much tougher it would get when circumstances forced them to launch the site weeks earlier than planned. They didn’t know for sure whether a no-name newcomer like CornerHardware.com could compete with new and upcoming E-commerce arms from brick-and-mortar brands like Sears (which was already selling parts, tools, and appliances online), Home Depot (which plans to launch a full E-commerce site this summer), and Ace Hardware (which would begin selling merchandise online at OurHouse.com late in 1999). In addition, dot-com start-ups were also racing to market. Major projects included HomeWarehouse.com, then under development in nearby San Mateo, Calif., and Amazon.com‘s new tools and hardware store, which would also launch by year’s end. And it was entirely likely that some of those in the race would end up as roadkill. When it came to CornerHardware.com’s technology, Hunt and Takata knew they weren’t looking just for a speedy job. Sure, there was no time to waste — they wanted a beta site before year’s end, a quiet launch by March 2000, and a public launch shortly after that. But building their Web site would also be a big, complex, cutting-edge project. They needed transaction processing capability and complete descriptions and images of some 37,000 products, everything from penny nails to power saws to Phillips-head screwdrivers. They would shoot to double their inventory, which is distributed from a warehouse in Kansas, within their first six months online. True to their customer-service mission, Hunt and Takata also wanted, from day one, to offer how-to articles, visitor message boards, animated step-by-step project instructions, a massive glossary of hardware terms, a superb search engine, and live customer service, online and in real time. That last capability would become, in fact, the real cornerstone, so to speak, of CornerHardware.com. Using interactive windows, customers would be able to chat with service reps in real time — asking questions about products or about a bill, for instance. That kind of service, which the company would contract out to dedicated staffers at Boston-based eSupportNow, would be what Hunt and Takata believed would ultimately distinguish their company not just from other online hardware stores but from their brick-and-mortar brethren as well. As Takata pointed out later, there weren’t many home-improvement stores that were open 24 hours a day. Although Hunt and Takata knew what they wanted their site to do, they didn’t know much about the nuts and bolts required to make it happen. They needed professional help. And they needed it fast. The high-speed, high-stakes scenario isn’t unique to CornerHardware.com — or even to the online home-improvement industry. Today almost any new business-to-consumer Internet company must fight for a foothold in an already crowded market. (Witness the proliferation of online pet stores, drugstores, vitamin stores, and toy stores.) Being first online remains a competitive advantage. But there’s no point in being first without doing it well. As consumers on the Internet grow more sophisticated they’re less willing to tolerate sites that are slow, unreliable, boring, or tough to navigate. And they absolutely won’t return to sites that haven’t provided stellar customer service. E-commerce sites have grown increasingly complex in reaction to the industry’s ever higher standards and well-publicized successes and failures. In many cases, like CornerHardware.com’s, a business simply can’t hire its own team to build a site — even if it could find the right people, it probably couldn’t afford to pay them or retain them. So, like CornerHardware.com, the company opts to stake the future of its business on outside developers — people the company doesn’t know, people who must translate the entrepreneur’s dreams and plans into equipment and software and code. Xuma’s approach bridges the gap between standard and optional E-commerce components. As Takata and Hunt were setting up shop in rented space in San Francisco’s financial district, Joe Cha was building his own business just a few blocks away. About a year earlier Cha had been working at his third consulting job. A friend reintroduced him to Jamie Lerner, a consultant Cha had known slightly when both had worked at Andersen Consulting several years earlier. Like Hunt and Takata, Cha and Lerner found themselves thinking along the same lines. They wanted to try something new, and they didn’t want to create just another San Francisco Web-development company. Instead their thinking went like this: What if you could apply the same approach to building a Web site that Dell Computer applies to building a computer? What if you could create big, complex, flexible, reliable, customized E-commerce systems in record time simply by not reinventing the wheel for every single project? So Cha and Lerner founded Xuma. (The name, pronounced “zoo-ma,” is an ancient Chinese battle cry that the partners found perfect to describe their army of engineers charging into the E-commerce wars.) They adapted the Dell model: just as Dell combines standard and optional components to rapidly create computers, Xuma combines its standard and optional E-commerce components to quickly build Web sites. In the venture’s first year, the quiet, charming Cha (so charismatic that he was among 10 bachelors featured in a Women.com feature on “The Men of Silicon Valley”) sold Xuma’s services to customers ranging from health-and-beauty-products retailer More.com to home-furnishings site GoodHome.com. By its second anniversary, in April 2000, Xuma had launched more than 70 Web-based businesses nationwide and employed 250 people in four offices. But back in mid-1999, Xuma hadn’t yet tackled anything on the multimillion-dollar scale of CornerHardware.com. By the summer of 1999, Takata, CornerHardware.com’s CEO, and Hunt, its chief operating officer, had raised about $6 million in funding: close to $1 million from their own pockets and from family, friends, and angels; and the balance from the first round of venture funding. (A second round early in 2000 would yield an additional $21 million.) And the founders had begun building a staff. Their first hire: vice-president of engineering Steve Finer, who faced the daunting job of actually overseeing the Web site’s construction. (See “Chronicles from the Pit,” below.) Finer, then 33, was an enthusiastic, outspoken technologist who, in a previous life, had managed nightclubs in Boston. He knew something about risk: he’d cofounded an Internet start-up that later collapsed and eventually filed for bankruptcy. And he knew something about working hard; he was always either at the office or connected to it by beeper, cell phone, or computer. (Shortly before the CornerHardware.com launch, when Finer was working 12 to 15 hours a day, he came home one night to find that his lonely dog, Cassius, had disemboweled a sofa cushion.) After joining CornerHardware.com in August 1999, Finer faced his first and toughest task: getting his new bosses “to understand that you don’t build anything — whether it’s a car or a Web site — overnight.” Especially not something as complex as CornerHardware.com. And in Internet terms, what Hunt and Takata wanted was pretty close to overnight. So Finer immediately ruled out doing the job in-house. Given the tight market for top technology staffers, especially in San Francisco, he knew he couldn’t build the talented team he needed to even approach that timetable. Instead, at his recommendation, CornerHardware.com looked outside, holding what Cha describes as a “bake-off” for potential developers late in the summer of 1999. Xuma wasn’t the oldest or the biggest or the best-known contestant. But Hunt, Takata, and Finer liked what Xuma had cooked up. The decisive factor: speed. Cha, Xuma’s CEO, and Lerner, its chairman and chief technology officer, then both 29, promised to do the job faster than anybody else — within six months. They also promised to build systems and databases that would “scale,” or grow quickly without having to be replaced. That’s what CornerHardware.com needed — and that’s why Xuma walked away with a contract worth between $750,000 and $1 million. (Takata says the balance of CornerHardware.com’s launch budget went for interface design, software licensing, equipment, product photography, and related costs.) By Xuma’s standards today — less than a year later — the CornerHardware.com contract is a relatively small one. But at the time it was a huge coup, providing, if all went well, a link in the chain leading to bigger jobs. So Cha took the kind of risk that he would later say no developer should ever take: he went ahead without any built-in contingency plan — no plan B — in case of crisis. True to its own business model, Xuma would build the CornerHardware.com site using many preexisting components — a standard credit-card-processing system, for instance. Still, the Xuma team, headed by senior project manager Phil Lew, then 26, knew that building such a complex E-commerce site wouldn’t be easy. Xuma anticipated it would spend five to six months, beginning in October 1999, building, testing, debugging, and launching the site. The schedule, though ambitious, seemed entirely possible. That is, as long as nothing went wrong. Although CornerHardware.com and Xuma were both new, fast-growing San Francisco­based start-ups, their cultures were entirely different. Sure, they both hired the best they could find: CornerHardware.com’s hiring coups included a Home Depot senior vice-president, a top producer from CNet, and several home-improvement authors and writers, while Xuma lured dozens of “rock-star engineers” away from other Web developers. But theirs were very different workplaces. At CornerHardware.com, a middle-aged artist or writer in a flannel shirt and jeans might sit in meetings with a college-age kid with a nose ring. It was rare for anybody to spend the whole night at work (with the possible exception of Finer, who worked around the clock in the countdown to the launch). In general, it was quiet, especially since most employees worked one or two days at home. (There wasn’t enough office space for everyone to be there at the same time.) In contrast to that relative calm, at Xuma nobody had a private office. Engineers racing to meet project deadlines spent days in the big war room known as “the pit,” living on trucked-in pizza or Thai food, working elbow to elbow at food-littered tables lined with computers. It was a noisy, messy, overwhelmingly youthful atmosphere. For Lew, it was exhausting, but it was also fun. His team bonded in a way that can come only from eating three meals a day together, working side by side until after midnight, then car-pooling home through unusually silent streets. And that bonding meant that together they felt they could do anything, Lew says. They would need to. In late fall, when Lew’s team was already spending most of its time in the pit simply trying to hit the original March launch date, something did go wrong. In mid-November, a CornerHardware.com competitor, HomeWarehouse.com, launched earlier than anybody had expected. About the same time, Amazon.com launched its home-improvement store, and Ace began putting OurHouse.com online. And funding was beginning to dry up for consumer dot-coms in favor of business-to-business ventures. Takata and Hunt decided they had no choice: they had to move the stealth launch from late March to January 15, and follow that with the public launch a few weeks later. They delivered the bad news to Finer, their liaison with Xuma. “They told me, ‘If we wait till March, we’re out of business,’ ” Finer recalls. “At that point I’m holding my stomach.” Finer reluctantly asked Xuma to shave close to six weeks off the initial launch date. Xuma agreed to try moving it up to January 15. “The trouble with being the vendor is that the customer is always right,” Cha says with a sigh. In this case, being right required heroics from Lew’s project team. “We had guys here that didn’t see their families, that were living here 24/7,” Cha says. (See Lew’s diary, below.) “We killed ourselves. But we got on-the-job training there. We learned.” What followed was a series of compromises made by both sides. Five days before the new launch date, the Xuma project team begged for an extension, saying they needed the extra testing time to make sure the site worked well. They asked for two more weeks. Takata and Hunt agreed to wait 10 more days. They knew they wouldn’t be doing themselves any favors by launching sooner if the site frustrated the very people they wanted to attract. Meanwhile, Lew was learning that both Hunt and Takata were demanding, detail-oriented, hands-on managers. “I used to say ‘Retail is detail,’ ” Takata says. “Now I say ‘E-tail is detail.’ ” Both Hunt and Takata closely tracked the site’s development, sometimes requesting changes that would take days of engineering time to complete. “Or they’d say, ‘We need 700 pages [of Web-site content before launch],’ ” Lew says. “We’d say, ‘We can do 200.’ “ Then there was the titanic tinkering on the day before the rescheduled launch. In the afternoon of January 24, Hunt decided the site needed another level of search hierarchy, or ways for customers to view products and information. While other team members frantically tested the site, one engineer spent six hours building in the new function, letting it go live around 8 p.m. After viewing the site that evening, Hunt changed his mind. Lew describes it this way: “Peter sees it. He doesn’t like it. I say, ‘It’s exactly what you guys asked for.’ He says, ‘I want it back like it was this morning.’ ” Lew asked Finer to intercede; Finer returned with this message from Hunt: “Sorry, but it has to happen. And you have to tell me when it’s done.” The same staffer spent the next three hours reversing his earlier work, finishing at about 1:30 a.m., just hours before the quiet launch. And yet Cha, ever the diplomat, doesn’t regard CornerHardware.com as particularly exacting. “All of our customers are very demanding,” he says. In fact, he adds, CornerHardware.com was a relatively easy client because, unlike many enthusiastic dot-com start-ups with ill-defined business plans, from the very beginning Hunt and Takata had clear ideas about what they wanted to accomplish. On January 25 at 3:30 a.m., Lew drove his entire team home from work, and, at 4:45 a.m., finally slept. CornerHardware.com had launched — without fanfare and without any major problems. It also launched without some of the things its founders had wanted. These were the trade-offs: CornerHardware.com had been photographing about 800 products a day, but even at that rate the company couldn’t shoot 37,000 products before the launch. Instead it posted a representative sampling from each category. (Says Hunt, “If you have 72 hammers on the site, do you really need pictures of all 72 from day one?”) It also launched with no way of issuing returns to customers’ credit-card bills. (Initially, refunds would be made by check.) And it launched with fewer products and less content than Hunt and Takata had wanted. But nothing crashed, and the products advertised were available, poised on the shelves in the Kansas City warehouse. Surprisingly, Takata rates the launch at about 95% of what he’d hoped for. “One of the lessons I have learned about the Internet space in general is that you can’t be a perfectionist,” he says. “The Internet is a game of weeks. If you can get your site up four weeks earlier and have a complete customer experience [even without some desired features], I’d say do it.” A month later the public launch went off without any major hitches. Since then, CornerHardware.com’s traffic has grown steadily, with Xuma continuing to run the site. Hunt and Takata won’t release figures except to say that they had more traffic in April than in the entire first quarter. As for the conversion rate — the percentage of people who actually buy something — “some days it’s 19% or 20%,” Hunt says. “And we have days where it’s 1%.” Meanwhile, the purchasing of big-ticket items has increased: in addition to batteries and lightbulbs, customers are buying bathroom vanities and power tools. These days the founders are still keeping an eye on the competition, especially that big orange company from Atlanta. “I’d be lying if I told you we don’t worry about Home Depot,” Hunt says. “But we don’t lose any sleep over it,” because, he says, he doesn’t believe the giant retailer will duplicate the CornerHardware.com business model or its real-time online customer service. As for that tree house, Hunt did build it much later. But he ended up creating it from a kit that he got from a brick-and-mortar retailer. Ironically, he got so busy starting up CornerHardware.com that he didn’t have time to build one from scratch. And in returning to that project, Hunt revisited one big lesson that he and Takata had discovered throughout the building of their business: it’s all about making compromises. Anne Stuart is a senior writer at Inc. Technology. Chronicles from the Pit Steve Finer, vice-president of engineering for CornerHardware.com, and Phil Lew, Xuma’s CornerHardware.com project team leader, each kept diaries for several weeks between the Web site’s “stealth launch,” in January, and its first major marketing pushes, in early March. Here are some excerpts: Steve Finer Thursday, February 17 At 3:45 a.m., we added another Sun Enterprise 4500 server with 16 CPUs. Serious horsepower! As I got off the elevator this morning my coworkers gave me a high five because the new server made the site so much faster. Wednesday, February 23 Two new applications went into alpha testing. One rotates products featured on the home page. The other is a media-tracking application [which tracks the effectiveness of promotional campaigns]. Unique visitors to the site have doubled since last week. Today the site was accessed from all over the world, including from Taiwan, Slovenia, Thailand, Malaysia, Israel, and Japan. Actually shaved for the first time in weeks. Wanted to be presentable for a taping we did today with Xuma and the Mark Bunting video crew [for a business video to be shown on United Airlines and TWA]. Thursday, February 24 Biggest challenge: preparing for the March marketing campaign [a newspaper and online ad campaign with coupons]. We need to be able to support the traffic. Friday, February 25 Added 6,000 new images. Finished quality-assurance process for media tracker and product-feature applications. Also [a New York Times] article gave us a nice boost in traffic and tripled the number of people who went to the customer-support line yesterday. Monday, February 28 We’re all really busy. The engineering team has a lot of projects that need to be completed, including the media tracker and the product-feature device. Tuesday, February 29 Public launch. It has been a difficult day. All departments are asking for additions to the site. It’s a challenge to satisfy all requests and prioritize them properly. Our lack of space [is a problem]. My job would be so much easier if we could hire people to supplement Xuma’s activities. Friday, March 3 We’re really focusing on driving traffic. We added a new disk drive to the development server and a new storage device to help manage all our images. We also added more than 40 new how-to articles. Don Johnson and Cheech Marin filmed their TV show, Nash Bridges, outside our office. We passed out CornerHardware.com hats to the crew, which they all wore during the filming. Saturday, March 4 Had one last meeting with Xuma and my staff to make sure we have the right staffing in place to support [Sunday's marketing campaign]. Monday, March 6 The marketing campaign went off without a hitch. We were able to support all the additional traffic. It blew my mind! Daily traffic today was more than double normal, and we had 10 times as many people buying products as we have on a typical day. Next week the campaign will branch out to a larger part of the country. Since everything today went so well, I’m not too worried. But it is still keeping me up at night. Phil Lew Thursday, February 24 Development seems to be going better than planned. [CornerHardware.com CIO Ken Hite] called me in the morning wanting to track an order number for an order where the money wasn’t captured. The problem was with the file from the third-party fulfillment house. Lesson learned: We need to build in more robust error checking. We cannot assume that the third-party fulfillment house will always give us the correct formatted file. The need to develop a robust process to keep the content and data fresh on the live site is giving me grief. [The process was so slow that when CornerHardware.com updated many items, it could take days for the updates to take effect.] We are working on another solution to load data but don’t know when that will be in place. The media-tracker application needs to be done by tomorrow (that is, in the hands of QA). Things are going great, but I’ve been down this road before. I need to keep the pressure on development to make sure that they follow through on our delivery dates. Friday, February 25 Had our first meeting with [new CornerHardware.com executive producer] Alice Hill. She had some fantastic ideas about the site direction. I look forward to working with her; she’s going to be able to streamline the decision-making process since we will not have to wait on [COO Peter Hunt and CEO Rich Takata] in the future for decisions about where the site is going to be heading. Sunday, February 27 What I’ll remember most about today: talking to Bill [Meehan, Xuma's lead engineer on the CornerHardware project] at midnight on a Sunday night about CornerHardware.com — again. We make this site go. Both of us take a lot of pride in that. We are both emotionally attached to this project and want CornerHardware.com to be the best it can be. That makes it easier to stay up late on Sunday nights to do things for CornerHardware.com. Monday, February 28 Everyone is very excited about the big day tomorrow [the official launch]. I think we have all done due diligence to get ready for this big day, but until the day comes you never know. Tuesday, February 29 Crazy, crazy day. In the afternoon, CornerHardware.com informed us that [there were] 40 additional content pages to be attached to a new front page. At 5 p.m., 6 p.m., 7 p.m., 8 p.m., this content had still not passed the QA check. The new front page will not be able to go up until tomorrow. Traffic was higher than usual. Two articles [about CornerHardware.com] came across my desk: one was from CNet and the other from ZDNet. Didn’t get much sleep, since we were at work until 5 a.m. Sunday, March 5 First thing I did when I woke up today was log on to the Internet via my DSL to check on the site [following that morning's newspaper coupon campaign]. I can see that the orders are already rolling in from Washington and Utah. By 10:30 a.m., we are already at 15 orders for the day. I called Steve Finer at home (I think I woke him up) and let him know the good news: people are hitting the site and buying things. Please e-mail your comments to editors@inc.com.

The Thing That Would Not Die

Model Community This inventive toy maker has an on-line community like you dream about. So how come they almost killed it? A short time ago, in a galaxy about 90 miles from Chicago, there was a hot little toy company that had a mysterious competitive weapon: an on-line customer community that really smoked. Only the rulers of the company didn’t quite get what a powerful weapon they had. It took a gutsy employee (with a knack for being really aggravating) to show how the right interactive Internet presence could help the business generate ideas, solve problems, and tap into customer passion for its products. The company: Playing Mantis Inc. of South Bend, Ind., manufacturer of die-cast cars, plastic-model kits, and action figures. The employee: Lisa Greco. In the physical world she is the company’s customer-service manager, opinionated and outspoken despite a Fargo-like midwestern cheer. On-line, however, she is something more mighty to behold. As moderator of the bulletin board dedicated to the company’s model kits, this single mom is a nurturing guide for the adult men who come to her bulletin board to talk about toys. She is Mistress of Monster Models. The Queen of Styrene. Simply put, Greco represents a customer’s pipeline into the heart of the company. That’s an incredible boon to hobbyists accustomed to traditional toy makers, which guard product information as if they were Napoleon Solo protecting nuclear firing codes. Playing Mantis, on the other hand, is available 24/7 on the boards. Anyone can ask questions or find out about new products. Moreover, toy-heads can safely indulge their love of the trappings of childhood without fear of being scorned as terminal nerds. What Playing Mantis gets is even more valuable. Through the boards it can reach the burning core of its customer base with company news, promotions, and quick-and-dirty survey questions. It can vet product ideas with real consumers before committing a dime to development. Last year alone, board members promoted new products, provided remedies for Web-site problems, and helped bring Playing Mantis to a new understanding of who was actually buying its stuff. And to think the company almost threw the whole thing away. Before we tell that story, let’s consider a simple proposition: In this world, men don’t grow up. That is no expert opinion, nor is it the result of painstaking research. It’s just common sense. Ask anyone who ever married one. Once we can agree on that, the whole story falls into place: why Tom Lowe, son of one of the world’s best-known entrepreneurs, started a company dedicated to reissuing lines of toys from the 1960s; how the company became successful despite the toy industry’s reputation for a competitive viciousness usually reserved for totalitarian nations; and how both Lowe and Playing Mantis discovered the secret formula (wouldn’t be much of a tale if it didn’t have a secret formula) for building a vibrant, successful on-line customer community — the Holy Grail of all E-commerce companies. Here’s the thing: most American men never, ever lose their passion for the playthings of their past. That’s why store shelves are packed with classic hits of the ’60s — Hot Wheels cars, Etch A Sketch, and the Duncan Butterfly Yo-Yo, to name a few. Toy makers know that parents make the big buying decisions and that fathers especially never lose affection for the toys they loved as kids. Which brings us to Lowe and his company. Walk into Playing Mantis and you’ll see drab offices, just like those of any typical light-manufacturing company, but with one exception. There are toys everywhere. Glass cases in the lobby display build-ups of the company’s Polar Lights line of model kits (mostly foot-tall figures of monsters, spies, and space robots). The walls are festooned with test shots and lineups of the company’s Johnny Lightning die-cast toy race cars. Employees’ shelves are packed with Pezzes and other playthings. Lowe’s own modest office is especially crammed with goodies. His shelves are filled with Playing Mantis products, and the walls are covered with framed photos of NASCAR champions and muscle cars. But Lowe’s real treasures are stowed behind a Cyclone security fence in the shipping bay. That’s where the boss keeps his personal stash of collectibles. He has enough Johnny Lightnings and Captain Actions there to make a grown man — should there be such a thing — swoon. But for all the play factor, the corporate headquarters is still basically a cube farm in the unglamorous burg of South Bend. Playing Mantis, founded in 1994 and still tiny by toy-industry standards, has only 40 employees and revenues of $15 million to $20 million. Most of the employees are locals. Half have been hired in the past two years. It doesn’t take too many strides for Lowe to reach any corner of his empire. Lanky, sleepy-eyed, renowned for his prankster sense of humor, he ambles around the building like a big kid. Stopping in his product-development department — a couple of banquet tables pushed together — he checks out some handcrafted prototypes from a new line of toy cars tentatively called “The Dreamboats” — family sedans from the 1950s, real Bulgemobiles. Lowe picks up a bloated Chrysler and offers his highest praise: “Rock on!” (Well, it’s a toy company, not the English-lit department at Columbia.) Lowe, 40, is firmly grounded in the tail-end baby-boomer demographic his company serves. He grew up in Cassopolis, Mich., which everybody calls Cass, amid the richest cultural influences of the ’60s: Mad magazine, monster movies, and good old-fashioned network television — oh, yes, and social protest and the Vietnam War. His father was the well-known entrepreneur Edward Lowe, inventor of kitty litter (somebody had to) and, by a number of accounts, a my-way-or-the-highway kind of guy. Lowe grew up mostly in the care of his mother, who, wonderfully, did not throw away his old toys. Never straying from his midwestern roots, Lowe graduated from Miami University of Ohio, earned his master’s in marketing at DePaul University in Chicago, and married his high school sweetheart. He sold for a food broker and did marketing work for Domino’s Pizza, but the corporate life was not much fun. “I was tired of being told what to do,” he says. In 1987, in Dundee, Ill., Lowe started his first company: Safe Care Products. Financing the effort with his own savings, Lowe was the company at the beginning. From his basement he developed products he knew he could sell to mass merchandisers. He had one hit toy — a Velcro football called the WhattaCatch — but most of his 30-some products were anonymous, you-never-thought-you-needed-it-until-you-saw-it-on-a-store-shelf items, such as a bathtub cushion and a Nintendo video-game lock called HomeworkFirst. The best stuff was yet to come. By the early 1990s, Lowe’s generation was rediscovering the toys they thought they had outgrown. In those pre-eBay days, the bible of this loose society of arrested adolescents was a magazine called Toy Shop, filled with classifieds featuring goodies from the preceding 40 years or so. Reading it, Lowe noticed that a lot of the stuff he had played with when he was a kid was selling for big bucks. That demand looked like one hell of an opportunity. Take Hot Wheels, for example. Introduced by Mattel in the mid-’60s ( You can tell it’s Mattel. It’s swell!), these little die-cast cars were engineered to roll freely and fast. They were a sensation — and still are. Although new Hot Wheels are on store shelves, some versions from the ’60s command hundreds of dollars each. Down in his mother’s basement lay all the toys Lowe had discarded back when he discovered girls, including about 50 Hot Wheels and 8 cars from the Johnny Lightning line. He initiated a trademark search. Mattel had a death grip on the Hot Wheels name, but the Johnny Lightning name had been abandoned years before. “Polar Lights is very special to me. …You’ve rekindled the joy I once felt when buying these kits. …You’re the only company who I feel a part of.” –Lou H. Through an ad in Toy Shop, Lowe says, he bought a collection that included 30 original Johnny Lightning cars. He brought the swag to Wal-Mart, notorious for being tougher than the A-Team when it comes to taking on new products. “Whattaya got here? A flea market?” the buyer roared. “I’ll give ya five minutes.” Lowe explained that he was going to re-create toys from the ’60s. “I was there for an hour and 15 minutes, explaining what my plan was,” he says. Wal-Mart bought in. Toys R Us did, too. Lowe was ready to rock. He sent his original Johnny Lightnings to China with a simple directive: copy these. And in 1995, Safe Care was reborn as Playing Mantis, a name he chose to be clever and kid friendly. “I always liked playing with praying mantises when I was young,” Lowe says, illustrating the difference between a Cass native and, say, some kid from Brooklyn. Lowe has always had one measure for deciding which products Playing Mantis will pursue: “If it isn’t cool, we won’t do it,” he says. He means it, too. This is his company all the way; he owns it free and clear. There isn’t even any long-term debt (“Just a working line of credit,” says chief financial officer Randy Miller), so the company has the resources to choose and develop its own products. “Being private is an important advantage. We can do what we want,” Lowe says. What he wants to do is to diversify enough to fight off challenges from the Hasbros and Mattels of the world. (Playing Mantis has already survived trademark-infringement litigation with Mattel. The suit was settled out of court.) He now has 2 solid brands; he’d like to build up to 10. And he has two secret weapons. The first: customers such as the guys on the bulletin board, gleeful pseudo-grown-ups who share his child-of-the-’60s sensibility. The second: his company’s ability to spin on a dime and give those guys what Lowe knows they want. That’s how he decided to revive a line of monster models originated in the ’60s by a company called Aurora Plastics Corp. In those years, Aurora models were bigger than Star Trek. Aurora produced model kits of classic monsters (like the Wolf Man and the Mummy) as well as characters from television (like Batman and Superman). And did they ever sell! “Those guys were easily putting out 200,000 or 300,000 units at a run. I’m sure some of the best-sellers, like Frankenstein and Dracula, were up there with sales of 2 million or 3 million apiece,” says Thomas Graham, professor of American history at Flagler College, in St. Augustine, Fla., and author of Greenberg’s Guide to Aurora Model Kits. “At the time, plastic models of all sorts were sold everywhere — in candy shops, drugstores, bicycle stores — and I even found mention of one mortuary. They were easy to find, they were inexpensive, and pretty much all your friends were building them.” By the 1980s, Aurora was gone, a victim of bad business decisions. With it went the entire market for monster models. The models weren’t missed until their original fans grew older and started searching for the icons of childhood — a pursuit that Graham claims is healthy. “The people I know who are living long and prospering are those who still enjoy playing,” he says. “Playing with toys in particular.” Take Lowe, for example. He built Aurora models as a kid and remembered one with special fondness: the haunted house from The Addams Family TV series. “I loved it,” he says. So in 1995, under the name Polar Lights (Get it? Aurora? Polar Lights?), Lowe had the kit re-created, offering it as a $60 exclusive at the high-ticket FAO Schwarz toy-store chain. The collector’s market went nuts. Original Addams Family house kits were selling in Toy Shop for at least $500. A year later, when the remade kit went into wide release at less than $25, a new market was born. Make no mistake: the days of 300,000-unit runs of a monster model are over. Most Polar Lights kits are produced in runs of 15,000 units. Yet Polar Lights has been successful enough for the line to be expanded to include 60-odd kits. To date, the most successful is a new original done in the Aurora style: a model of the Jupiter 2 spaceship, the interstellar Winnebago featured on the TV series Lost in Space. Playing Mantis launched Polar Lights just as intelligent life was being discovered in cyberspace. In late 1995 and early 1996 — through bulletin boards on Prodigy, America Online, and other services — collectors, craftspeople, and genre fans were discovering whole communities of like-minded souls. Lowe and his managers caught on to the phenomenon — sort of. In 1995 they stuck up a quick site, just some early brochureware. But for serious marketing, Playing Mantis held fast to traditional methods — newsletters and print ads. Part of the reason for going slow on the Web was that Lowe was no fan of online customer interaction. “I would do chats and look at boards on AOL, but I found that I didn’t get a lot of new ideas from them,” he says. “Besides, there are some vicious people out there. Some of the employees who left would get on the boards and say things that just weren’t true. There were competitors who got on there just to screw around with you. I might go on to see what’s being said, but in terms of being Tom Lowe on the boards, I don’t do it anymore.” But Greco had no such reservations. She and Hank Hagquist, an outside contractor who was Playing Mantis’s original Web master, were old friends from Riley High in South Bend. Hagquist was running his own site, called Hobbytalk, for fans of radio-controlled car models. He talked to Greco about starting a section devoted to Playing Mantis products. “I thought they could be a good subject,” he says. “I thought the people who bought or collected their products were real enthusiasts, people with a passion.” In 1998, Hagquist established a board for Polar Lights, moderated by Greco. Dave Metzner, the company’s product-development manager for model kits, helped Greco answer board members’ questions. But it was she who ruled the board. Judiciously leaking product news, insisting on cordial relations and polite language, Greco — signing missives with an enthusiastic “Moi!” — gathered a loyal cadre of fans to her cyberclubhouse. Yet even after hundreds of members had signed on, she didn’t fully understand the potency of the boards until Polar Lights released that model of the Jupiter 2. The kit, enthusiastically received, had a flaw: a hatch inside the ship was upside down. That detail would escape 99.9% of normal buyers. But this was the Internet, where obsessive behavior hangs its hat. Board members were all over the error, and Metzner, with Lowe’s approval, decided to correct the flaw for the second run of the kit. The online critics felt as if they had spoken and the company had responded. True enough, says Metzner. “If it hadn’t been for people telling us about it, it wouldn’t have been fixed,” he says. It was the kind of action that converts loyal customers into devoted fans. As the online community jelled, its members got very comfortable with one another. Their exchanges strayed way beyond toys. In the course of a limerick contest initiated by Greco ( There once was a monster named Frankie, in the mood for a little hanky-panky… What say we just don’t go there?), one member posted a message revealing that his wife had left him. “Why share it out here like this?” he wrote. “I don’t know. Thanks for the support out here, you guys.” Greco responded immediately — “We’re here for you” — and the board members pitched in. It brought home for Greco just how much this community meant to its members. The board was a sanctuary that connected them to the company and to one another far more deeply than she had realized. “As I reflect back on my hobby experiences for the year, one of the most satisfying has been the relationship formed by a large number of us with Polar Lights. It is not their products that, I feel, sets them apart from other model companies. It is their devotion to the consumer.” –PCModeler.com Unfortunately, Lowe was not frequenting this board (or boards that were set up later for Johnny Lightning and Captain Action fans), so he saw little of all that. What he did see was that Greco and Metzner were spending an awful lot of time on the Internet. It didn’t seem as though their involvement with the boards was adding much to the business. “That’s what they were doing with their time?” Lowe remembers asking. “Talking to people about their problems, which have nothing to do with model kits? So we took a very hard look at that.” At the time, in 1998, Playing Mantis was already reexamining its entire customer-service function. By 1999 some customer-service staffers were being asked to do more active selling. That’s how it happened that the boards almost died. It started with Hagquist, who was still hosting the virtual community on his site. “At some point I was saying that here we have this multimillion-dollar company building its name for free,” he says. “C’mon, guys, feed a little back.” So he gave Greco a deadline: By the end of February, start paying him $50 a month for each of the three boards. Greco filed all the appropriate paperwork, never imagining there’d be a problem. But Miller wouldn’t approve the expense at first. Look at it from his point of view. For one thing, it is often his job, as with any CFO, to be the one who says no when it comes to using company resources. For another, he and Lowe were already wondering what the true cost of the boards was and whether they were worthwhile. “It wasn’t really a financial decision as much as a decision regarding use of time,” Miller says. “Intangibles like that make for the toughest decisions.” As the deadline approached, Greco grew nervous. If the boards shut down, it would be a disaster — and not just for the company, which would lose a resource that she felt hadn’t even begun to pay off. “This community, and I think most communities, are built on trust,” she says. “These boards are a refuge for the guys, a place where they can be themselves. Shut it down, even for a day, and you create an uncertainty from which the community might never recover.” She went to Metzner for advice. Of all people he best knew what was happening on the boards. Together they decided that even if they had to pay the fee themselves, they’d keep at least the model-kit board running. But first Greco wanted to reach out to Lowe directly. It wasn’t politically correct, and it would anger her managers, but it wouldn’t be the first time she had gone right to the top. (Greco was once a guard in a prison for men, and she prides herself on being pretty tough.) “I felt I owed the fight to the guys out there,” she says. On February 22, Greco posted a new topic on the Polar Lights board. Under the title “Hypothetical Question” she wrote, “Good morning, guys! Everyone have a cup of coffee? Anyone bring the donuts Time for a little sidebar discussion. SUPPOSE, just suppose, this BB would cease to exist. How would you all feel about that?” That week the boards hummed. Members figured that something was going on in South Bend. Member Steve Iversen, who under the nom-de-Web CultTVMan operates a popular site for builders of science-fiction models, E-mailed his list of 700 subscribers, urging them to register their support. In post after post, members expressed their need for the board: “Polar Lights is very special to me. … You’ve rekindled the joy I once felt when buying these kits. … You’re the ONLY company who I feel a part of.” –Lou H. “It helps us to be kids again. … It’s easier to be a kid again when you see there are a bunch of other people doing it: you feel less guilty/silly!” –David Redknap “As I reflect back on my hobby experiences for the year, one of the most satisfying has been the relationship formed by a large number of us with Polar Lights. It is not their products that, I feel, sets them apart from other model companies. It is their devotion to the consumer.” –PCModeler.com