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Building and buying great software for metal manufacturing

Healthcare.gov’s disastrous rollout tells metal manufacturers what to avoid when looking into software, its quality, and how it was developed.

multicolored code on a computer screen

Software is becoming ever more relevant and critical for the modern fab shop. Whether you are developing code in-house or shopping for a third-party tool, it’s important to understand what you are looking for. That can be difficult without having a deep understanding of how software is made.

Healthcare.gov represents an easily accessible case study on the risks of software design. It launched 10 years ago and immediately landed with a thud. It was so slow and glitchy that as few as 1% of interested people were able to enroll in the first week. The web design failed to deliver on the absolute basics, with poor workflows and glitchy user interfaces. To top it off, health insurance providers were provided inaccurate information by the site, making it difficult or even impossible to correctly handle enrollments.

Stress tests that should have explored expected user volume were wholly inadequate. A day before launch, it was found that the site became too slow with only 1,100 concurrent users. The expected user count was 50,000 to 60,000. If that wasn’t bad enough, the actual simultaneous user count soared to 250,000 within the first week, over 200 times the number of users that pre-release stress tests indicated the site could handle. In retrospect, one wonders why the stress tests were performed at all. Their clear failure did nothing to change the release timeline.

The project didn’t stumble for lack of budget. It was originally estimated to cost $93.7 million, a staggering sum even if the project didn’t go over budget. But the estimates were wildly incorrect. Before completion, the total cost rose to a jaw-dropping, tear-inducing $1.7 billion, almost 20 times higher than estimated.

Healthcare.gov works great in 2023, but at launch it was perhaps the most spectacular, expensive, and public software fiasco in history. While much of the complexity surrounding Healthcare.gov’s rollout was unavoidable, we can use its botched rollout to explore what makes software projects succeed or fail. Its failures might provide insight into how you might build your own in-house software team. It might also provide insight into what to look for when buying third-party software.

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