I used to do a good bit of supervisor training. There was one topic that was especially difficult to get across: coaching. The core concept of the module spoke to the value of simply talking with operators and employees about the work they were doing and eliciting ideas from them as to how it might be done more safely, more easily and more efficiently.
The majority of the supervisors just didnt seem to be able to grasp the idea that they could simply engage in two-way conversation with employees about their jobs. They found it difficult to avoid giving one-way feedback (usually of the constructive type), giving directions or making recommendations themselves. They viewed their own roles as talking to rather than talking with employees.
I never fully understood this reluctance to talk with employees about their own work without a preconceived agenda because Ive found it to be very effective in my own work as a manager and a consultant. In fact, Ive come to believe that simple conversation with managers, staff and operating employees is central to the success of any lean enterprise implementation.
Through these conversations, ideas are developed, unforeseen problems and barriers are identified, roots of existing problems are uncovered, questions are answered, concerns are addressed, and, most important of all, interest and energy is created and spread. In my own experience, substantial and positive changes have been made to lean deployment plans based on information gathered through such conversations. Had the changes to the approach not been made, the success of the entire implementation would have been jeopardized.
In one case, I was helping my employer, a high end hotel firm, carry out an employee survey at one of its operations. We had held any number of planning meetings with all the right managers, and the effort was ready to move ahead. No one had mentioned any possible problems with our plans. During a lunchroom conversation with a supervisor, I learned that a similar survey had been conducted five years previously. Once the results of that survey were compiled and reported, two managers lost their jobs. Negative results from employees in their departments were given as a reason for their dismissal. Acting on this information, we announced that the results of the survey would be given only to the managers at that hotel and not to anyone at the corporate office. The hotel managers would be responsible for developing a plan to respond to the survey results and communicating that plan to corporate officers.
Headquarters had a bit of trouble buying into the idea but eventually agreed. The total quality initiative that we subsequently deployed led to that hotel going to the top of its category in measured customer satisfaction.
In several other cases, Ive found that employees who attended and actively participated in workshops on 5S and quick setup didnt actually acquire a full understanding of the value of those tools. 5S was seen as simply another approach to housekeeping and quick change only as a way of reducing machine downtime. In these cases, Ive been able to correct these misperceptions before they impacted the initiative.
