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Building Accountability to Drive Continuous Improvement
Whether trying out a simple new process or embarking on a complex continuous improvement project, it’s imperative that you have a sound technical solution to make it work, but it’s also critical to have a sound change management strategy to make it last.
In any major change initiative, there will be 10% to 20% of the affected population who will readily support the change regardless of what it is. These “early adopters” are an uncommon but essential breed who thrives on change almost solely for the sake of change itself. They recognize change as an essential part of evolution. These individuals need little incentive other than a basic explanation of what it is they are being asked to do, maybe a little training, and mostly support of leadership to let them move forward unimpeded.

At the other end of the spectrum is another 10% to 20% who will oppose change for the very same reason: that it’s change. These are “resisters” who see change as a bad thing, regardless of the potential benefits it could bring. They are content with the way things have “worked” for years, and see change as a threat to the status quo. These individuals typically find it difficult -- if not impossible -- to make even minor change happen, whether at work or at home.
In between these two poles is a majority of the population who starts out neutral. They take a wait-and-see attitude toward change until they are swayed either toward the positive end by a compelling argument about what’s in it for them and why it’s a good thing, or toward the negative end by a lack thereof.
The ultimate success of any change initiative lies in holding everyone accountable for doing their part in implementing the technical solution. Early adopters will most likely be self motivated to do whatever they need to do. Those who they can sway toward their way of thinking will be easily influenced to do the same. For these groups, accountability is generally not an issue.
Resisters -- both active and passive -- often pose the largest impediment to the success of organizational change, and along with that the biggest challenge to front-line leadership. These individuals may require additional oversight, and holding them accountable often means ensuring that there are consequences for not following established guidelines.
Unfortunately, in many organizations, and for many managers, accountability equates to some form of discipline. While that may ultimately be necessary, it should be a last resort and should only be considered after careful evaluation of the situation.
A Question of Responsibility
When something doesn’t get done right, the first question to ask is whether the person you expected to do it actually knew it was their responsibility. It isn’t fair to hold someone accountable for something they honestly didn’t know they were supposed to do. For example, if I go on vacation and don’t ask my neighbors to get my mail and newspaper, I can’t blame them when I come home to an overstuffed mailbox and a driveway full of paper. The first step of accountability is to clearly set expectations for what is to be done and by whom.
Having cleared that hurdle, the next question is whether the person has the appropriate knowledge to do what you wanted them do. It isn’t appropriate to hold someone accountable for something they legitimately don’t know how to do. In fact, if they haven’t been given the proper instructions, it might be better if they DON’T do it.
Resisters -- both active and passive -- often pose the largest impediment to the success of organizational change.
For example, my kids never expressed any interest in helping me mow the lawn until one day my youngest daughter said it looked fun and asked if she could give it a try. Not wanting to miss this window of opportunity, I fired up my self-propelled mower and turned it over to her with no more explanation of what to do than which lever to push. She did exactly as I instructed, took off, and about 10 steps later landed squarely in the trunk of a big maple tree.
Both my daughter and the tree escaped unscathed; the mower wasn’t quite so fortunate. Having clearly demonstrated that she did not have the proper level of training -- and making me dig a little too deep into my shallow Scottish pockets to repair the mower -- we both agreed that she would most likely never be held accountable for cutting the grass.
A Matter of Competency
But knowing how to do something doesn’t necessarily mean that you have the ability to do it; that comes with practice. Until someone has demonstrated competency to do something repeatedly the way it is supposed to be done, it’s not right to hold them accountable for doing it.
That little incident with my daughter serves as a reminder when my wife asks me to remind her how to use the snow blower. She has used it before to clear our driveway but doesn’t do it regularly, and it could be hazardous, if not deadly, to expect her to do it, especially when I’m not home. A cracked mower housing is one thing. I don’t want to be responsible for having my wife sustain a serious injury because I didn’t ensure that she was properly trained on how to operate a potentially dangerous piece of equipment.
Once you determine that expectations have been clearly set, that the appropriate level of education/training has been provided, and that there is demonstrated competency, then and only then can someone be truly held accountable for doing something effectively, efficiently and safely. At that point it becomes either a matter of individual desire to execute the assigned task, or basic management skills to make sure it happens.
If people ultimately can’t or won’t do what is rightfully expected of them, it is up to front-line management to find out why and determine an appropriate course of action. For example, is it due to time constraints? Is it due to resource availability? Are there organizational roadblocks that need to be removed? Are there underlying personal issues? If it simply comes down to a matter of personal choice, then there must be repercussions.
Resisters need to have expectations restated and understand what the implications will be for continuing to choose not to follow the process. This could be anything from an informal discussion (i.e. coaching) to more formal steps up to and including time off or even termination in extreme situations. That may sound harsh, but most of management’s time and energy should be spent focusing on the people who are doing things right, not those who are doing it wrong.
Accountability may ultimately require discipline, but hopefully this demonstrates that discipline is the last step -- not the first -- in accountability. True accountability -- and the sustainability that results from it -- comes from developing a good technical solution to a challenge and using good change management skills to clearly set expectations, provide the necessary training, ensure demonstrated competency, determine the root cause for gaps and implement the right corrective actions to fix them.
We are all accountable for our own actions, and in that sense it could be argued that accountability ultimately rests with the person responsible for following the process. However, a portion of accountability also rests with the person who developed the technical solution in the first place. And because almost any technical solution requires people to make it successful, a great deal of the accountability also resides with front-line supervisors. They must have the change management knowledge, skills, and competency to make sure that any organizational change is implemented and sustained.
Here’s a simple checklist that summarizes the points above and can be used as a quick reference for front-line supervisors or anyone else to determine exactly where accountability lies:
- Did you know it was your responsibility?
- Were you properly trained on how to do it?
- Have you demonstrated that you can do it?
If the answer to any of these three questions is “no,” then you need to go back and reassess the situation before taking any further action with your employees.
Doug Wallace is a senior consultant and materials management subject matter expert for Life Cycle Engineering (LCE). In addition to his materials management expertise, Doug is knowledgeable in planning and scheduling and operator care best practices. He is also certified in Prosci’s Change Management methodology. Doug can be reached at dwallace@LCE.com.

A Shared Purpose: Leadership and Culture at COVID-19 Innovators
As entire segments of the economy sit idle, the stories, thankfully, are many, of manufacturers swiftly shifting their operations from their usual products and components to items necessary in the fight against COVID-19. Automotive manufacturers, for instance, are reaching deep into their vast, complex supply chains to source the hundreds of parts needed to make ventilators—and enlisting their highly trained workforces to assemble them. Running-shoe manufacturers are using their stock material in new ways to produce high-grade face masks. High-tech metalcrafters are deploying their 3D-printing equipment and expertise to print die-inserts for protective shield parts. And don’t forget the whiskey distillers, like tiny Wolf Spirit Distillery and many other distilleries from miniscule to ginormous, who quickly shifted to making hand sanitizer for healthcare workers as soon as they heard there was a need.
Which got us thinking: What leadership and cultural traits distinguish a company that can pivot its operations quickly as needed, from one that takes months or years to make any big changes. And what are the benefits, both tangible and intangible, of such efforts?
Earlier this month, IndustryWeek Tech Editor Peter Fretty reached out with a survey to a multitude of manufacturing companies innovating in response to COVID-19. Forty-five companies responded, sharing their approaches and challenges and giving a window into their operations and culture. There were some common themes around leadership in their responses—themes that should resonate with companies looking to inject innovation into their own operations.
A Shared Purpose
Some manufacturers are discovering strengths they never knew they had. “Companies who otherwise would find multiple reasons why something cannot be done manage to remove barriers quickly and find ways to say, ‘Yes, we can do that,’ and ‘You can count on us’ during this crisis situation,” wrote Deborah Jennings-Conner, UL’s director of global life and health sciences regulatory and testing. Having a shared purpose is making them more open to new ways of doing things and streamlining their processes.
Manufacturers successfully innovating around COVID-19 “will have learned much about quality control and the fact that you cannot inspect product quality at the end of the production line, but rather must build quality into the entire process, starting with the design,” Jennings-Conner added.
These companies are also reaching beyond their comfort zones and finding new ways to partner—we see that with automakers and medical device companies, for instance, sharing expertise and resources. Dave Jordan, global head of consulting and services integration for Tata Consultancy Services, says that as the economy shifts and the fragility of supply chains is laid bare, relationships will spring up in unlikely places. “We’ll see less resistance to shifting towards a partnership mindset, even those that violate conventional wisdom, to meet the new normal—especially if that means cooperation and collaboration among competitors, versus not coming back at all,” Jordan responded.
Continuous Improvement
Manufacturers that have dedicated themselves to developing a culture of continuous improvement are finding that already having people and systems in place, working together and knowing each others’ jobs and work styles, are benefiting them in new ways in a crisis. Plastic bag maker CMD Corporation, for instance, was able to pivot to making face shields quickly because it had already developed an in-house 3D Printing Group to enhance its production. “Because we have multiple people that understand the technology, we were able to utilize the skills of Adam, a manufacturing engineer working from home to program the parts, and Garrett, a manufacturing engineer working in the plant, to run the parts. Thus they shared the workload,” the company wrote in the survey.
Prioritizing product improvement allowed Mirage Systems, manufacturer of parachutes, to quickly pivot to making mask covers. “We’re constantly working on ways to improve ourselves,” they wrote. “For instance, comfort is often forgotten when creating a product that saves lives. We know the importance of making our products comfortable—because that makes the difference when end users wear them all the time. We also understand how making things look great makes a difference—and we’re focusing on detail over detail every day.”
R&D
Dan T. Moore, a group of manufacturing companies that make everything from Army helmet pads to green roof trays, shifted to manufacturing ventilators during the crisis. CEO Dan T. Moore III says that investing 5 to 8% of annual sales in new technology and “having a strong bench of technologists” enables the company to respond quickly to new opportunities or changes in the market. “Keeping a strong balance sheet so you can take calculated risks and having a diversified portfolio which is not dependent on any one part of the economy” are also key, he says.
3D Systems
JMA, a maker of 4G/5G communications equipment now making ventilator systems, agrees that investing in highly skilled tech people helps make an organization more nimble. “With the skills we have on-hand from machine, electrical and software engineers, we were able to pivot some key people and have them laser focus on this project in order to develop a plausible solution,” said the company in its response.
A “start-up, rapid-response culture” allowed Nufabrx, maker of medicated fabrics like compression socks and carpal tunnel gloves, to pivot to making $2M worth of masks to healthcare providers in less than two weeks. And Mohawk Flooring’s “first to market” mindset (it was a pioneer in 100% recyclable carpeting) inspired employees to investigate where they could innovate to help their community in a crisis. Mohawk is now manufacturing gowns, masks and faceshields
The benefits of being able to quickly pivot during a crisis? Keeping employees employed, boosting morale, making processes more nimble and efficient, and creating new opportunities for partnerships and new types of products to manufacture. Sounds like a winning way to operate.
Main Photo: A worker making face masks at a New Balance facility.
Second Photo: Medicated swabs being printed at 3D Systems.







