United Dreamliner makes emergency landing in New Orleans









A brand-new United Airlines "Dreamliner" bound for Newark, N.J., was diverted Tuesday morning, making an emergency landing in New Orleans because of a mechanical problem.

The Boeing 787 Dreamliner recently entered service in North America in a debut last month with United Airlines. United and Boeing are both based in Chicago.

United flight 1146 from Houston to Newark was diverted to Louis Armstrong New Orleans International Airport and landed safely, the airline said. The flight carried 174 customers and 10 crew members.

"We are re-accommodating the customers on a different aircraft to Newark," United said in a statement. "United will work with Boeing to review the diversion and determine the cause."

The Dreamliner, which features greater passenger comforts and fuel efficiency compared with similar planes, is a big deal for United and Boeing and has been highly touted by both.

gkarp@tribune.com

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4 ex-federal prosecutors finalists for U.S. attorney post








The names of four former federal prosecutors will be sent to the White House for the Obama administration to decide who will succeed former U.S. Attorney Patrick Fitzgerald, according to a letter made public by Illinois’ two U.S. senators.

Several sources have previously identified the finalists as Jonathan Bunge, Zach Fardon, Lori Lightfoot and Gil Soffer.

According to the letter sent to the White House, Democrat Dick Durbin and Republican Mark Kirk conferred on the candidates and agreed on the four names.

Lightfoot, a partner at the Chicago law firm of Mayer Brown, would be the first African-American and first woman appointed to the post in Chicago. While working for the city from 2002 to 2005, she headed the Police Department's Office of Professional Standards, which investigated complaints of misconduct by officers.

Bunge, a partner at the Kirkland Ellis law firm, led the federal prosecution of police officers in south suburban Ford Heights who were convicted on racketeering and bribery charges.

Fardon, a partner at the Latham Watkins law firm, helped win the conviction of former Gov. George Ryan in 2006 as part of the Operation Safe Roads probe. Fardon, who grew up in Tennessee, also brings administrative experience, serving in the No. 2 post in the U.S. attorney's office in Nashville before entering private practice.

Soffer, a partner at the Katten Muchin Rosenman law firm, served as associate deputy attorney general in Washington during the final year of President George W. Bush's administration. He was appointed to an Illinois state ethics commission in 2009.

Fitzgerald stepped down in June after serving a record nearly 11 years as Chicago's chief federal prosecutor. He joined the law firm of Skadden, Arps, Slate, Meagher & Flom LLP in Chicago late last month.


asweeney@tribune.com






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A bachelorette no more: Ashley Herbert weds beau












NEW YORK (AP) — Ashley Hebert (AY’-behr) is no longer a “Bachelorette.”


The 28-year-old Maine native got hitched over the weekend in Pasadena, Calif., to 35-year-old J.P. Rosenbaum of Long Island, who proposed to her on the seventh season of the ABC dating reality show “The Bachelorette.” Hebert tweeted that “12/1/12 goes down in history as the best day of my life!!”












Natalia Desrosiers, spokeswoman for Warner Bros. Television, which produces the show, said the wedding will be aired on Dec. 16 on ABC.


Hebert, who also competed on the 15th season of “The Bachelor,” grew up in Madawaska, Maine, and is a dentist. The couple now resides in the New York City area.


Only one other couple that met on the TV show has married. Bachelorette Trista Rehn married Vail, Colo., firefighter Ryan Sutter in 2003.


Entertainment News Headlines – Yahoo! News


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Software Programs Help Doctors Diagnose, but Can’t Replace Them





SAN FRANCISCO — The man on stage had his audience of 600 mesmerized. Over the course of 45 minutes, the tension grew. Finally, the moment of truth arrived, and the room was silent with anticipation.




At last he spoke. “Lymphoma with secondary hemophagocytic syndrome,” he said. The crowd erupted in applause.


Professionals in every field revere their superstars, and in medicine the best diagnosticians are held in particularly high esteem. Dr. Gurpreet Dhaliwal, 39, a self-effacing associate professor clinical medicine at the University of California, San Francisco, is considered one of the most skillful clinical diagnosticians in practice.


The case Dr. Dhaliwal was presented, at a medical  conference last year, began with information that could have described hundreds of diseases: the patient had intermittent fevers, joint pain, and weight and appetite loss.


To observe him at work is like watching Steven Spielberg tackle a script or Rory McIlroy a golf course. He was given new information bit by bit — lab, imaging and biopsy results. Over the course of the session, he drew on an encyclopedic familiarity with thousands of syndromes. He deftly dismissed red herrings while picking up on clues that others might ignore, gradually homing in on the accurate diagnosis.


Just how special is Dr. Dhaliwal’s talent? More to the point, what can he do that a computer cannot? Will a computer ever successfully stand in for a skill that is based not simply on a vast fund of knowledge but also on more intangible factors like intuition?


The history of computer-assisted diagnostics is long and rich. In the 1970s, researchers at the University of Pittsburgh developed software to diagnose complex problems in general internal medicine; the project eventually resulted in a commercial program called Quick Medical Reference. Since the 1980s, Massachusetts General Hospital has been developing and refining DXplain, a program that provides a ranked list of clinical diagnoses from a set of symptoms and laboratory data.


And I.B.M., on the heels of its triumph last year with Watson, the Jeopardy-playing computer, is working on Watson for Healthcare.


In some ways, Dr. Dhaliwal’s diagnostic method is similar to that of another I.B.M. project: the Deep Blue chess program, which in 1996 trounced Garry Kasparov, the world’s best player at the time, to claim an unambiguous victory in the computer’s relentless march into the human domain.


Although lacking consciousness and a human’s intuition, Deep Blue had millions of moves memorized and could analyze as many each second. Dr. Dhaliwal does the diagnostic equivalent, though at human speed.


Since medical school, he has been an insatiable reader of case reports in medical journals, and case conferences from other hospitals. At work he occasionally uses a diagnostic checklist program called Isabel, just to make certain he hasn’t forgotten something. But the program has yet to offer a diagnosis that Dr. Dhaliwal missed.


Dr. Dhaliwal regularly receives cases from physicians who are stumped by a set of symptoms. At medical conferences, he is presented with one vexingly difficult case and is given 45 minutes to solve it. It is a medical high-wire act; doctors in the audience squirm as the set of facts gets more obscure and all the diagnoses they were considering are ruled out. After absorbing and processing scores of details, Dr. Dhaliwal must commit to a diagnosis. More often than not, he is right.


When working on a difficult case in front of an audience, Dr. Dhaliwal puts his entire thought process on display, with the goal of “elevating the stature of thinking,” he said. He believes this is becoming more important because physicians are being assessed on whether they gave the right medicine to a patient, or remembered to order a certain test.


Without such emphasis, physicians and training programs might forget the importance of having smart, thoughtful doctors. “Because in medicine,” Dr. Dhaliwal said, “thinking is our most important procedure.”


He added: “Getting better at diagnosis isn’t about figuring out if someone has one rare disease versus another. Getting better at diagnosis is as important to patient quality and safety as reducing medication errors, or eliminating wrong site surgery.”


Clinical Precision


Dr. Dhaliwal does half his clinical work on the wards of the San Francisco V. A. Medical Center, and the other half in its emergency department, where he often puzzles through multiple mysteries at a time.


One recent afternoon in the E.R., he was treating a 66-year-old man who was mentally unstable and uncooperative. He complained of hip pain, but routine lab work revealed that his kidneys weren’t working and his potassium was rising to a dangerous level, putting him in danger of an arrhythmia that could kill him — perhaps within hours. An ultrasound showed that his bladder was blocked.


There was work to be done: drain the bladder, correct the potassium level. It would have been easy to dismiss the hip pain as a distraction; it didn’t easily fit the picture. But Dr. Dhaliwal’s instinct is to hew to the ancient rule that physicians should try to come to a unifying diagnosis. In the end, everything — including the hip pain — was traced to metastatic prostate cancer.


“Things can shift very quickly in the emergency room,” Dr. Dhaliwal said. “One challenge of this, whether you use a computer or your brain, is deciding what’s signal and what’s noise.” Much of the time, it is his intuition that helps figure out which is which.


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Heat is on Groupon's Andrew Mason









In June 2011, Groupon Inc. Chief Executive Andrew Mason took the stage at a conference hosted by influential technology blog AllThingsD.


When co-executive editor Kara Swisher asked him whether an initial public offering was coming soon, he shot her what she later dubbed his "death stare."


The audience laughed and broke into applause.





The tone was decidedly more subdued last week, when Mason found himself at another tech industry confab, fielding questions from Business Insider's Henry Blodget, this time about whether Groupon's directors were going to fire him at their meeting the next day. AllThingsD had reported a day earlier, citing anonymous sources, that Groupon's board of directors was considering replacing Mason with a more experienced CEO to lead the Chicago-based daily deal company's turnaround.


The contrast between those two appearances underscores the swift and dramatic tumble of Mason's standing in tech and business circles within a few years. The young founder and CEO graced the cover of Forbes in 2010 and was named Ernst & Young's National Entrepreneur of the Year in the "emerging" category a year later.


Those accolades are a far cry from the cloud hanging over Mason, 32, and the company he launched four years ago. The leak to AllThingsD appeared to be deliberately timed to embarrass the executive, forcing him to field questions about his own competence at a scheduled appearance. This public hint of internal strife has fueled speculation around Mason's fate even as other public tech companies, such as Facebook and social game-maker Zynga, have also seen their stock prices drop since their IPOs.


Groupon's board met Thursday and took no action on the CEO's job, with company spokesman Paul Taaffe saying the board and management were "working together with their heads down to achieve Groupon's objectives."


Markets, however, seemed unconvinced. Groupon's beleaguered stock closed slightly higher Thursday but dropped 8.7 percent to $4.14 Friday. Shares debuted at $20 in November 2011.


Investors "want experience in leadership," said Raman Chadha, a clinical professor at DePaul University and co-founder of the Junto Institute for Entrepreneurial Leadership, a training program for startup founders. "And as a result, where Andrew's background was cool and sexy — and maybe even bordering on amusing — when Groupon was a pure startup, that's in the mindset of those of us who are observers and supporters … and fellow entrepreneurs. I think in the minds of the investor community and Wall Street, (it's different) because now the company has a lot more to lose. And if it's going to fall, it's going to fall really hard and really far."


For Chadha, Mason's unconventional pedigree as a music major-turned-startup-founder was part of the appealing, media-friendly story of Groupon's origin. The company was launched as recession-weary consumers were eager for deals, and it achieved rapid growth while earning a reputation for antics like decorating a conference room in the style of a fictional, possibly deranged tenant of Groupon's headquarters who had lived there before the startup moved into the offices.


The scrutiny of Groupon was tremendous given the "high-flying" nature of the company, said David Larcker, a corporate governance expert at the Stanford Graduate School of Business.


"You have a founder as CEO," he said. "He's the public face of the company. He has set the culture. All of that stuff."


That culture, driven in large part by Mason, turned from a lovable quirk to a major liability as the company ran into controversy over its poorly received Super Bowl ads in February 2011 and a series of missteps in the run-up to its IPO. Then, within months of its public debut, it disclosed an accounting flaw that forced it to restate financial results.


The larger question surrounding Groupon is the long-term viability of its basic business model. The company has been expanding offerings beyond its core daily deals, which have seen growth rates tail off. It's also dealing with a recession in the key European market as well as continued competition in the U.S.


But the biggest challenge facing Mason now is probably his own performance, or rather the perception that he isn't up to the task of running the global, publicly traded business worth billions that he founded but that now needs a turnaround. The stock is down 80 percent from its IPO price.


"It's an oft-told, oft-expected story that the genius entrepreneur steps aside when he or she succeeds at building a company big enough to need an experienced CEO," said Erik Gordon, a business professor at the University of Michigan.


The example Gordon and others cite is Google, which flourished after its co-founders Larry Page and Sergey Brin made way for a more seasoned executive in Eric Schmidt.


"The Google guys did it, and the results were spectacular," Gordon said.


Chadha said many startups tend to become more corporate in outlook, and less quirky, as they grow, because they bring in experienced executives from large companies that may have difficulty adapting to an entrepreneurial culture or reject it outright as not professional enough.


"I think that's where Google is very different," Chadha said. "(The company) sought out entrepreneurial, startup types — people that became part of their management team." That free-form element of Google's culture comes out in such things as the Google doodles — the offbeat tributes to notable anniversaries or famous people that pop up on the main search page.


Mason has acknowledged areas where Groupon needs to improve and has hired senior executives with experience at more mature tech companies. That hasn't always worked either. Margo Georgiadis, who came from Google as chief operating officer, returned to that company after five months.


Whether there's still room for Mason on the top management team remains to be seen. He was direct in his interview last week with Blodget, offering a minimum of jokes as he focused on discussing the job he and others at Groupon must accomplish.


"I care far more about the success of the business than I care about my role as CEO," he said.


A year ago, when he spoke to author Frank Sennett for his book "Groupon's Biggest Deal Ever," Mason was unapologetic about his management style.


"You only live once, and all I'm doing is being myself," he told Sennett. "I think a normal CEO is trying to appear in some way that's not actually them. That's probably not what they're like."


In the same book, former President and Chief Operating Officer Rob Solomon offered this blunt assessment of his ex-boss: "Andrew at thirty-five and forty is going to hate Andrew at twenty-nine and thirty; I guarantee it."


Melissa Harris and Bloomberg News contributed.


wawong@tribune.com


Twitter @VelocityWong





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4th quarter: Seahawks 17, Bears 14









Robbie Gould's 45-yard field goal as time expired in regulation sent the Chicago Bears into overtime Sunday tied 17-17 with the Seattle Seahawks at Soldier Field.


A 56-yard Jay Cutler pass to Brandon Marshall set up the tying kick.


Rookie quarterback Russell Wilson engineered a 97-yard drive for a touchdown to give the Seahawks a 17-14 lead with 24 seconds to play. Russell capped the drive with a 14-yard TD pass to Golden Tate.





Cutler had put the Bears back on top in the third quarter, hitting Matt Forte on a 12-yard touchdown pass for a 14-10 lead at the 3:10 mark. The officials initially ruled Forte down just inside the 1. Coach Lovie Smith challenged the spot and the officials then ruled it a touchdown.


Seattle took a 10-7 into halftime on a 31-yard field goal by Steven Hauschka. The Seahawks appeared initially to score a touchdown when Wilson passed 14 yards to Braylon Edwards into the end zone with 10 seconds left. But the play was reviewed and determined that the ball was trapped.


Seattle had tied the game on a 4-yard touchdown run by Marshawn Lynch with 2:15 left until the half. The nine-play, 94-yard scoring drive included a 49-yard pass from Wilson to Tate.


Cutler, who entered the game with a 13-2 record in his last 15 starts, delivered during the Bears' first drive. Lynch fumbled with 11:59 left in the first period when Brian Urlacher forced the ball away and Kelvin Hayden recovered at the Seahawks' 49. The Bears converted the turnover into a 12-yard touchdown pass from Cutler to Earl Bennett with 8:33 left.


Bennett was hit low by Brandon Browner inside the 5-yard line and flipped into the end zone. The Bears led 7-0 with Robbie Gould's extra point.


Bennett later was ruled out with a concussion. Safety Chris Conte was ruled out due to illness.


Cutler completed 10 of 16 passes for 125 yards and one TD in the first half for a passer rating of 107.6. The Bears had just 41 yards rushing at the intermission.


Marshall had seven first-half catches for 94 yards.


Since Week 16 of the 2009 season, the Bears had compiled a 27-10 record (.730) in games Cutler has started. He had completed 659 of 1,103 passes (59.7 percent) for 8,144 yards, 57 touchdowns and 35 interceptions for a passer rating of 86.6.

fmitchell@tribune.com

Twitter@kicker34





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Apple to sell new iPads, iPhone 5 in China in Dec.












CUPERTINO, Calif. (AP) — Apple Inc. on Friday said its latest iPad models will go on sale in China on Dec. 7, followed by the iPhone 5 a week later.


China is one of Apple‘s largest and fastest-growing markets. Analyst Brian White at Topeka Capital Markets said iPhone 5 is launching roughly when he expected it, but he hadn’t expected the iPad mini and the fourth-generation, full-size iPad to go on sale in China this year.












“Our conversations during our meetings and casual consumer interactions during our China trips tell us that the iPad Mini will take off like wildfire in China,” White wrote in a research report Friday morning. “The smaller form factor and lower price point, we believe Apple will be able to sell the iPad mini in meaningful volumes.”


White said uptake of the iPhone 4S was relatively slow in China, because the signature new feature, voice-recognition-powered virtual assistant Siri, did not understand Mandarin Chinese. With this year’s software update, Siri now does understand the language, which should encourage upgrades, he said.


Gadgets News Headlines – Yahoo! News


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“Twilight” shines in third box office win over Bond












LOS ANGELES (Reuters) – The “Twilight” teen movie vampires sucked more money out of theaters over the weekend, leading James Bond, Brad Pitt and the rest of box office pack with $ 17.4 million in U.S. and Canadian ticket sales and scoring its third weekly win.


Pitt’s new movie, the small-budget gangster film “Killing Them Softly,” bombed with filmgoers who panned it with a rare “F” grade on average in polling by audience survey firm CinemaScore. The movie landed in seventh place with $ 7 million in ticket sales at domestic theaters.












The results were much brighter for “Breaking Dawn – Part 2,” the fifth and final film in the “Twilight” vampire and werewolf saga, which has earned $ 254.6 million at North American (U.S. and Canadian) theaters since its smash debut on November 16.


The top rankings were similar to last week’s Thanksgiving holiday weekend.


Bond movie “Skyfall” starring Daniel Craig as superspy 007 grabbed $ 17 million and held on to second place, according to studio estimates compiled by Reuters. Steven Spielberg‘s historical drama “Lincoln,” featuring a critically acclaimed performance by Daniel Day-Lewis as the 16th U.S. president, kept the No. 3 slot with $ 13.5 million.


A week ago, “Breaking Dawn – Part 2″ and “Skyfall” helped push the five-day Thanksgiving weekend to a box office record. The success of the two films, plus upcoming releases such as fantasy prequel “The Hobbit” and musical “Les Miserables,” are likely to power 2012 ticket sales to an all-time high, according to industry forecasts.


As of Sunday, year-to-date sales were running 5.9 percent ahead of the same point in 2011 at $ 9.9 billion, box office tracker Hollywood.com said.


Critics were kinder than audiences to Pitt’s “Killing Them Softly.” Seventy-nine percent of reviews collected on the Rotten Tomatoes website applauded the film, which blends a violent but comic gangster story with criticism of politicians’ failure to address the economic crisis.


In the movie, Pitt plays a hitman brought in by mafia bosses to eliminate a group of thieves who raid a high-stakes poker game. The film is set in an unspecified U.S. city marked by abandoned houses, closed shops and petty criminals and mobsters trying to get by.


The Weinstein Company distributed the movie, which was produced for less than $ 20 million by Annapurna Pictures, Inferno Entertainment, and Pitt’s production company, Plan B Entertainment.


In the No. 4 slot, family movie “Rise of the Guardians” captured $ 13.5 million. The Dreamworks Animation film has taken in $ 48.9 million since its Thanksgiving weekend debut, one of the slowest starts for a movie from the studio behind “Shrek” and “Kung Fu Panda.”


“Guardians” features the voices of Chris Pine and Alec Baldwin as the Tooth Fairy, Santa Claus and other childhood favorites who save the world.


Rounding out the top five, survival story “Life of Pi” earned $ 12 million and fifth place. The critically praised film from director Ang Lee is based on a book about a boy stranded on a boat with an adult Bengal tiger. Its two-week domestic total reached $ 48.4 million.


The other nationwide release, horror thriller “The Collection,” took in $ 3.4 million and finished in tenth place. The movie, a sequel to 2009 movie “The Collector,” tells the story of a serial killer who kidnaps women.


“Breaking Dawn – Part 2″ was released by Summit Entertainment, a unit of Lions Gate Entertainment. Sony Corp’s movie studio distributed “Skyfall.”


“Lincoln” was produced by Dreamworks and distributed by Walt Disney Co. Viacom Inc’s Paramount studio distributed “Rise of the Guardians.” News Corp’s 20th Century Fox studio released “Life of Pi,” and LD Entertainment distributed “The Collection.”


(Reporting By Lisa Richwine and Christine Kearney; Editing by Cynthia Osterman)


Movies News Headlines – Yahoo! News


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Opinion: A Health Insurance Detective Story





I’VE had a long career as a business journalist, beginning at Forbes and including eight years as the editor of Money, a personal finance magazine. But I’ve never faced a more confounding reporting challenge than the one I’m engaged in now: What will I pay next year for the pill that controls my blood cancer?




After making more than 70 phone calls to 16 organizations over the past few weeks, I’m still not totally sure what I will owe for my Revlimid, a derivative of thalidomide that is keeping my multiple myeloma in check. The drug is extremely expensive — about $11,000 retail for a four-week supply, $132,000 a year, $524 a pill. Time Warner, my former employer, has covered me for years under its Supplementary Medicare Program, a plan for retirees that included a special Writers Guild benefit capping my out-of-pocket prescription costs at $1,000 a year. That out-of-pocket limit is scheduled to expire on Jan. 1. So what will my Revlimid cost me next year?


The answers I got ranged from $20 a month to $17,000 a year. One of the first people I phoned said that no matter what I heard, I wouldn’t know the cost until I filed a claim in January. Seventy phone calls later, that may still be the most reliable thing anyone has told me.


Like around 47 million other Medicare beneficiaries, I have until this Friday, Dec. 7, when open enrollment ends, to choose my 2013 Medicare coverage, either through traditional Medicare or a private insurer, as well as my drug coverage — or I will risk all sorts of complications and potential late penalties.


But if a seasoned personal-finance journalist can’t get a straight answer to a simple question, what chance do most people have of picking the right health insurance option?


A study published in the journal Health Affairs in October estimated that a mere 5.2 percent of Medicare Part D beneficiaries chose the cheapest coverage that met their needs. All in all, consumers appear to be wasting roughly $11 billion a year on their Part D coverage, partly, I think, because they don’t get reliable answers to straightforward questions.


Here’s a snapshot of my surreal experience:


NOV. 7 A packet from Time Warner informs me that the company’s new 2013 Retiree Health Care Plan has “no out-of-pocket limit on your expenses.” But Erin, the person who answers at the company’s Benefits Service Center, tells me that the new plan will have “no practical effect” on me. What about the $1,000-a-year cap on drug costs? Is that really being eliminated? “Yes,” she says, “there’s no limit on out-of-pocket expenses in 2013.” I tell her I think that could have a major effect on me.


Next I talk to David at CVS/Caremark, Time Warner’s new drug insurance provider. He thinks my out-of-pocket cost for Revlimid next year will be $6,900. He says, “I know I’m scaring you.”


I call back Erin at Time Warner. She mentions something about $10,000 and says she’ll get an estimate for me in two business days.


NOV. 8 I phone Medicare. Jay says that if I switch to Medicare’s Part D prescription coverage, with a new provider, Revlimid’s cost will drive me into Medicare’s “catastrophic coverage.” I’d pay $2,819 the first month, and 5 percent of the cost of the drug thereafter — $563 a month or maybe $561. Anyway, roughly $9,000 for the year. Jay says AARP’s Part D plan may be a good option.


NOV. 9 Erin at Time Warner tells me that the company’s policy bundles United Healthcare medical coverage with CVS/Caremark’s drug coverage. I can’t accept the medical plan and cherry-pick prescription coverage elsewhere. It’s take it or leave it. Then she puts CVS’s Michele on the line to get me a Revlimid quote. Michele says Time Warner hasn’t transferred my insurance information. She can’t give me a quote without it. Erin says she will not call me with an update. I’ll have to call her.


My oncologist’s assistant steers me to Celgene, Revlimid’s manufacturer. Jennifer in “patient support” says premium assistance grants can cut the cost of Revlimid to $20 or $30 a month. She says, “You’re going to be O.K.” If my income is low enough to qualify for assistance.


NOV. 12 I try CVS again. Christine says my insurance records still have not been transferred, but she thinks my Revlimid might cost $17,000 a year.


Adriana at Medicare warns me that AARP and other Part D providers will require “prior authorization” to cover my Revlimid, so it’s probably best to stick with Time Warner no matter what the cost.


But Brooke at AARP insists that I don’t need prior authorization for my Revlimid, and so does her supervisor Brian — until he spots a footnote. Then he assures me that it will be easy to get prior authorization. All I need is a doctor’s note. My out-of-pocket cost for 2013: roughly $7,000.


NOV. 13 Linda at CVS says her company still doesn’t have my file, but from what she can see about Time Warner’s insurance plans my cost will be $60 a month — $720 for the year.


CVS assigns my case to Rebecca. She says she’s “sure all will be fine.” Well, “pretty sure.” She’s excited. She’s been with the company only a few months. This will be her first quote.


NOV. 14 Giddens at Time Warner puts in an “emergency update request” to get my files transferred to CVS.


Frank Lalli is an editorial consultant on retirement issues and a former senior executive editor at Time Warner’s Time Inc.



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Designer made herself into a manufacturer

Shoemaker Annie Mohaupt nearly closed down a year ago after her move to make sandals in China proved a bust. In the year that followed, she started her own factory in Chicago, producing and selling her luxury wooden shoes. (Posted Dec. 1st, 2012)









Shoemaker Annie Mohaupt nearly closed down a year ago after her move to make sandals in China proved a bust. The sandals could easily be pulled apart.

She looked into what it would cost to make her sandals in another country but returned production to Chicago. The decision, she said, allows her to tap into growing demand for U.S.-made products and to utilize manufacturing technology that makes her company, Mohop Inc., a global competitor.






"I have a factory," Mohaupt said, her statement reflecting her evolution from thinking of herself solely as a designer. As a manufacturer she understands she has control over the quality of her products — a key to sales and growth. "I'm happy but it's also intimidating. There is a lot to manage and wrap my head around."

Mohaupt's tale is illustrative of what manufacturing experts and politicians have been saying for quite some time: American manufacturers can be successful and create jobs by using the latest technology in producing and developing products.

So far this year, Mohaupt has sold about 1,500 pairs of sandals for about $158,000, she said. Mohaupt credits Facebook fans and word-of-mouth recommendations for a 500 percent increase in sales this fall over a year ago, and she expects to sell about 5,000 pairs of sandals in 2013. When she reaches annual sales of 10,000 pairs, Mohaupt said she'll need to invest in more equipment, like a new wood-cutting machine.

"I want for her to be making her shoes in the U.S.," said Greg Kaleel, owner of American Male & Co. a family-owned retail shop in Oswego, adding that his customers will pay more for shoes made here. "That's how important the 'made in America' is."

On a recent evening, the sweet smell of burned walnut filled Mohaupt's basement shop in a three-story building in Chicago's River West neighborhood. The smell emanated from a computerized machine about the size of a pingpong table cutting walnut blocks into triangles with concave curves and arches. Those curves support the heel and arch of a woman's foot and create a sleek, sophisticated look.

An architect by training, Mohaupt, 37, feeds her three-dimensional designs into a program that converts it into letters and numbers and tells the machine where to cut. That was the easy part for her to learn. To operate the machine, Mohaupt relied on a tutorial from the machine-maker and learned the rest via the Internet.

The soft-spoken woman employs three people, including an office manager and a young designer. If sandals sell as planned, she would hire four to six temporary workers in the spring. That's when sales typically ramp up after the winter lull. Mohaupt wants to expand her product line to lessen her dependence on sandal sales. One idea is a moccasin she can sell in the cold months.

Mohaupt has come a long way since 2005, when she cut and glued layers of plywood by hand to make her sandals. Her early versions featured a cylindrical wooden heel and elastic loops on each side of the sole that acted as guides for ties or ribbons that customers could change at will — her signature design.

She sold her first sandals for $70 at a craft fair and appeared to be off and running. The bliss of her success crumbled the following morning when customers complained that the shoes easily came apart. The heels broke off and the loops snapped. In effect, the stumble marked the beginning of her apprenticeship as a manufacturer.

Mohaupt spent the next year quizzing seasoned shoemakers and shoe repairers about how she could improve the quality of her shoes. Ultimately, she decided that her sandals should be able to withstand 100 miles of use. To test her designs, she wore her sandals while taking her dog on five-mile treks.

"I lost some weight," she said. She also test-marketed the evolving sandals by mailing samples to her first customers. Some got up to five pairs as Mohaupt developed — and later patented — a system to keep the elastic loops in place. One problem licked, she then focused on the labor involved.

Cutting the plywood by hand was grueling work in its own right. And then she had to glue together the layers. "I would end up covered in glue," she said.

So Mohaupt began experimenting with wooden blocks, which she'd sculpt with a saw into wedges. That eliminated having to glue together layers of plywood but still was physically draining.

That's when she made a decision that would forever change her business. In 2009 she bought on credit a $70,000 computer-driven machine that could read her 3-D designs and cut heels in minutes, saving hours of labor. The machine also allowed Mohaupt to experiment with new designs. For example, she could for the first time produce curved heel bases and make shoes with added arch support.

Demand grew steadily, which should have been a good problem. But even with the machine she couldn't keep pace with orders. Mohaupt tried training people to make the sandals but found that she couldn't train them and make shoes at the same time.

That's when she first considered outsourcing production. She tested a Canadian shoemaker but severed the relationship after it sent her a shipment of poorly made shoes. Mohaupt also was unsuccessful in lining up production in Argentina.

Then, suddenly, a competitor emerged that jolted her into making a decision that ultimately would nearly bring down her company. The competitor was selling sandals almost identical to hers and nudging her sandals out of local shops she had supplied for years. Its prices also were lower because it was producing its sandals in China. She faced being driven out of business, she said.

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