Jim Carr on Rebranding a Machine Shop, Leading Through 2008, and Getting Out of Your Comfort Zone

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Overview

Jim Carr has spent decades at CARR Machine & Tool, the shop their father founded in 1972. On this episode of Manufacturing Happy Hour, recorded at the company's new facility in Elk Grove Village, Illinois, host Chris asks what it means for a contract manufacturer to "look and act differently than a typical machine shop." Carr's answer runs through their early job as a bartender, the 2008 recession, an early bet on social media, and a new building designed from the ground up. Throughout, Carr keeps returning to two convictions: people advance by stepping slightly outside their comfort zone, and they succeed by finding work they are passionate about.

19 min read

Chris opens by noting that Carr was one of the first manufacturing podcasters they ever listened to, back when Chris was living in San Francisco and listening in a climbing gym's weight room. Carr jokes that listeners heard "all my tears and all the problems we were having" at the company, and adds that they are still living it.

From Printing Presses to Aerospace

Asked for an elevator pitch, Carr describes CARR Machine & Tool as an aerospace contract manufacturer whose work typically serves space and exploration, aviation, medical, and emerging technologies. Carr calls this "quite a reversal" from the 1980s, 1990s, and early 2000s. Back then the company served the commercial printing industry, making new and replacement parts for the presses that printed major newspapers such as the Chicago Tribune and the Boston Globe. Carr describes that work as "pretty lucrative." When Chris suggests the company diversified because Carr could see where the printed-newspaper market was heading, Carr agrees "100%."

Carr's father founded the company on December 2, 1972. A photo in the conference room shows him racing stock cars at Soldier Field in the 1950s. According to Carr, their father was working full time as a machinist then, and he and his friends would buy new cars and modify them for the track. The car in the photo is, Carr believes, a 1958 Ford, and the picture shows their father taking a victory lap with the checkered flag out the window. Carr describes him as a driven man who liked to put in long hours and who had the mechanical aptitude the industry needs. He liked working on cars and could take an engine apart.

What a "Typical Machine Shop" Used to Mean

Before explaining how CARR tries to be different, Chris asks what a typical machine shop looks like. Carr says it depends on who you ask. A younger person might picture a high-tech operation. Carr grew up as a baby boomer seeing manufacturing treated as a second-class industry and a second-class career choice for people without an education, and generally regarded as low-paying.

Carr says that picture is completely out of date and wants to "lead the charge" in telling the world so. In Carr's view, parents especially need to learn that the industry is now high-tech and well paid, and that someone can support a family for an entire career working for a manufacturer.

Designing a Building to Match the Customers You Want

The new facility, Carr says, was deliberate. The company was running out of room in its old building and its capabilities were growing. Carr's son Ryan had joined the business, and they wanted a significant change. Carr saw the move as their one remaining chance to make the company their own. The old building had been their father's, and Carr says they always felt they were living under his shadow.

So Carr set out to build what they imagined a first-class aerospace manufacturer looks and acts like. The company hired an architect, an interior designer, and a separate designer to work out the most efficient layout for the machines on the shop floor. Carr calls it "an endeavor," but says they knew there would be only one chance to do it right and believes they did.

The goal was to appeal to higher-end OEMs and aerospace companies that Carr thinks could take the business to the next level. Carr names Tesla, Virgin Galactic, and SpaceX as examples of high-end, high-tech companies. Carr's reasoning is that matching your brand to the companies you want to attract creates good synergy. Chris notes that the front of the building has the same intentional feel: offices and a conference room, then a lounge down the hall for entertaining customers, so the layout follows the natural flow of a customer visit.

The Bartending Lesson: Touch It Once

That lounge reflects a background most shop owners don't have. In their twenties, while working full time at CARR, Carr tended bar in the evenings and says that is where they learned what hospitality is about. Carr sees their career as combining that hospitality background with a lifetime in manufacturing, and adds a third interest, marketing.

Chris asks for the most tangible lesson from bartending that helped in manufacturing. After thinking for a moment, Carr recalls a manager's advice during training. A cocktail waitress arrives with fifteen drink orders: an extra-dry vodka martini, an old-fashioned, a Manhattan, an Old Style, a rum and Coke, a Bacardi and Coke. If you pick up a bottle, the manager said, pick it up only once and pour every drink that needs it before you set it down.

Carr turned that into a principle: if you are going to do something, do it once, and touch each item only once. Carr gives shipping and receiving as an example, where the aim is to do as much as possible in a single pass. Carr still remembers the row of fifteen iced glasses, with a two-ounce pour for a Bacardi martini next to a Bacardi and tonic. Chris points out that the lesson could easily have been about hospitality but turned out to be about process.

Expanding the Box: The Pong Metaphor

Chris notes that Carr has made several big moves recently, including the new building (just down the street from the old one, but much larger) and a new podcast, My True Position. How do you know when it's time for a change like that?

Carr says you have to feel it. People get caught up in daily life, living inside a bubble or a box, and eventually they get tired and need a spark. Carr's metaphor, one they say they've shared on many podcasts, is the old video game Pong: a ball bouncing back and forth inside a simple rectangle. Most people, Carr says, live their lives and careers inside a box like that, and it stays the same size for decades.

Carr's advice is to push the sides out by an eighth or a quarter of an inch. A change that small won't be painful, only a little uncomfortable, and the discomfort doesn't last. Once the bigger box feels comfortable, you push out again, and the box keeps growing. Carr frames this as an ongoing practice: stay outside your comfort zone until it becomes comfortable, then move into the uncomfortable zone again.

Chris asks whether the spark could be superficial rather than strategic. Carr says that sometimes you just have to go for it. Failure is fine because you learn from it. The important thing is not to overextend so far that failure would be fatal. "Baby steps forward," Carr says, "baby steps into the uncomfortable zone." Chris adds that as old discomforts fade, new ones appear with each new thing you try, and Carr agrees.

2008: Layoffs and a Turning Point

Chris asks when Carr first realized they needed to expand the box, especially given that a family company can feel set in its ways. Carr took full ownership of the business in 2004 and says they remain its sole shareholder and president. Then came 2008, which Carr calls one of the worst recessions the industry has seen.

Carr had to lay off 65% of the workforce, one employee at a time, roughly one a week, telling each person there was no more work. Carr says the emotional strain nearly made them sick. But Carr also found that dreading each conversation was worse than having it. Employees often responded with something like "I get it, Jim, it's okay," because they watched the news and knew how bad the economy was. Carr concluded they had agonized more than necessary.

The recession convinced Carr that the company needed more networking, more marketing, and more sales. In Carr's assessment, that was what had been holding the business back: it wasn't global enough, and people didn't know about it. Carr says they have always been drawn to creative people, including marketers, and through friendships with marketing people discovered both a love for the work and a natural talent for self-promotion. Carr never looked back.

When Ryan joined in 2014, Carr saw a chance to put that passion to work. Ryan would run operations while Carr ran sales and marketing. Carr says this is the right seat after an entire career. Carr still has the mechanical skills (running CNC machines, GD&T, programming), and Chris says the shop tour showed Carr "still got the chops." But Carr's passion is leadership, branding, and marketing.

Building a Personal Board of Directors

Chris asks what advice Carr would give someone who will have to lead through hard times. Carr's answer is networking, and tells how their own network grew. CARR had belonged to a local manufacturing association for decades without really getting involved. The association then hired a marketing manager, Kent Gladish, to help members market themselves. Carr and Gladish were about the same age and had similar interests, and they started talking about marketing. Gladish kept urging Carr to join committees and attend events.

Through those activities Carr met like-minded peers in the industry. That led to a seat on the association's board of directors, then its executive team, and then chairmanship of the board in 2016. Carr says the result is a "solid personal board of directors" built over the past ten to twelve years: a small core group Carr can call about a business problem and meet over a beer, a glass of wine, or a martini to talk it through. Carr says this advice applies at any stage of a career, noting, "I started late, but I did it."

Rocks and Accountability

Chris mentions My True Position, noting that it gives listeners a transparent look behind the scenes of Carr's shop, sometimes about something that happened on the floor an hour before recording. On that show, Chris heard Carr talk about quarterly "rocks."

Carr explains that as part of building a roadmap for growth, the company read Traction by Wickman, which lays out EOS, the Entrepreneurial Operating System. Within EOS, "rocks" are quarterly and annual goals. You commit to one, and you are held accountable for whether you achieved it. When the company knew it needed to move, Carr's rock for one quarter was "find a building." Once that was done, the next quarter's rock was "buy the building." Pointing around the room, Carr says, "Here we are. This is a rock." For Carr, the point is setting goals, telling the team about them, and being accountable to the team, because "everyone needs accountability in life."

Chris admits that despite being goal-oriented, they sometimes realize late in the year that a goal from three quarters earlier never got done. Carr says that's okay. If you genuinely tried, and you are the only one who knows how hard you tried, you have gained experience and resources for the next similar goal. Chris says that as a new solo entrepreneur, they are still looking for the right accountability group.

Where the Branding Instinct Came From

Turning to marketing, Chris notes that branding doesn't come naturally to most manufacturing leaders. Carr's father, after all, was known for mechanical skill and drive. Where did Carr's focus on brand come from?

Carr says they eventually realized "you get what you pay for." Carr uses Nordstrom as an example: most people have a clear impression of what shopping at an upscale store like that is like, and that impression is its brand. Carr's father used to say, "Jim, for 10 cents more you can go first class." It was said half in jest, and the gap is no longer ten cents, but the message was to spend a little more and get something nice. Carr says they took that idea further.

For Carr, branding means asking what people think of when they think of CARR, and then being relentlessly consistent. The way a company presents itself to the public has to be the same every time.

An Early, Skeptically Received Bet on Social Media

Chris points out that Carr adopted social media, LinkedIn, and podcasting well before most of the industry. Carr traces it to about fifteen years ago, when their kids were in high school. Carr watched them on the family computer using MySpace, and then Facebook as it was emerging, and saw how absorbed they were. Carr sat and watched over their shoulders, trying to understand it, and decided it could be a great way to promote the business, since companies were only beginning to appear on social media.

Carr remembers that peers in the manufacturing association thought they were "nuts" for posting about the company, because it was new and different. Chris adds that when they started in 2016, people could at least write it off as a young person using social media. Carr was already a seasoned executive. Carr's attitude was, "What the hell have I got to lose?" and calls it an example of making the box bigger. In Carr's view, what holds most people back in their careers is worrying too much about what others think. Carr says you have to do what feels right for you and live authentically, and calls that realization a big "aha moment."

Why keep going without immediate results? Carr's reasons are that it's free marketing, free branding, and the fastest way to get the word out. Carr compares it to newspapers, the industry CARR once served: by the time a printed paper reaches you, the news is old. Carr remembers learning that Michael Jackson had died from an obscure person's Facebook post.

Does It Pay Off? Thought Leadership More Than Attributable Sales

Asked whether social media has brought in new business, Carr says they can't say for sure. What Carr is confident of is that it built thought leadership and promoted the brand. Carr's hypothesis is that a prospective customer who is on the fence might see Carr's presence online, conclude "this guy knows his crap," and that might tip them over to CARR and "seal the deal."

Chris agrees and says they can point to a few specific relationships and clients that came from their own podcast. But Chris thinks consistency matters more: a steady voice and posting schedule add up over time. Chris calls it a form of storytelling that others can't replicate overnight. Chris says they followed the story of CARR's move through Carr's posts and podcast without knowing exactly where they learned it. Carr says they enjoyed posting video teasers of the building's progress.

Carr admits to posting less than before, citing time, but keeps a steady schedule for the podcast. "More is more" on social media, Carr says, but consistency matters most. If you post only two or three times a week, do it on the same days and at the same times, just as a podcast releases on a set day, because inconsistency "confuses people, and people don't like to be confused."

Why Other Manufacturers Hold Back, and Carr's Posting Formula

Chris asks why more manufacturers don't approach marketing this way. Carr says they don't really know. One guess is that manufacturers tend to be reclusive and introverted, and Carr sees themselves as an exception. Another is that people get scared of what they don't understand. A newcomer worries about getting a post right, but Carr says a post doesn't have to be perfect, just good.

Carr's own approach focuses on the image, because you have "a millisecond" to catch someone scrolling. Carr keeps the text short, since they personally don't like reading a lot: picture, idea, what's it about, and the reader either stays or moves on. Chris notes that long written posts work well for others, so the takeaway is to find your own style. Chris adds that a bad post simply disappears within hours, while a good one might help even one person, which Chris compares to making a sales call.

Carr adds a caveat: social media isn't everything. If marketing is a pie, Carr puts social media at close to 25%, but not quite. The rest includes a good website, good video, good imagery, and a strong brand, meaning "the feeling," not just a logo, with everything consistent. Carr says the logo still has to match the brand, because many people don't realize how much a logo defines it. Chris notes that CARR's logo has an aerospace feel. Carr confirms that's intentional and points out how simple it is, just the "A." When the graphic designer presented it, Carr knew within about 30 seconds that it was right, because it evoked the right feeling.

Staying Young: Passion and the Right Seat

Chris asks what keeps Carr young at heart, energetic, and still trying new things when a baby boomer this far into a career could be coasting. Carr says someone asked the same question two nights earlier. The answer is that Carr likes to work, is passionate about it, and is in the right seat, leading the company's vision, and happier in their career than ever before.

Carr gives employees the same message in performance reviews: it's not about Carr or the company, it's about them. Without passion, Carr tells them, they will never be fully happy or reach their highest level or income. Carr encourages them to find that passion, whether at CARR or elsewhere. If it's at CARR but they're in the wrong role, Carr asks them to say so, and offers to create a new role or move them into one where they will thrive.

Preparing for the Next Generation

In the final question, Chris asks how Carr is preparing the company to reflect the vision of Ryan and the rest of the team. Carr's answer is brief: think strategically about succession, plan for the long term rather than the short term, and share that vision with the whole team. Carr sums it up as "transparency."

Asked whether anything was left out, Carr repeats the two beliefs from a long career. First, pushing yourself outside your comfort zone is essential to advancing in both personal life and career. Second, passion for your work is critical to growth, promotion, and success.

The episode ends with the question it began with, about drinks. Carr's wife drinks almost only white wine, so the couple drinks a lot of Chardonnay. Their current favorite is a high-end Napa Valley Chardonnay from the Carneros area. It's not an everyday bottle, Carr notes, adding that once you start drinking wine in that category, it raises your baseline for what an everyday wine should be.