By August 27, 2005 1 Comments Read More →

Strong Supervision: The Key to Long-term Kaizen

Kaizen and Lean Manufacturing thoughts | Gemba Panta Rei

This is a great article by Jon Miller from the Panta Rei lean blog.

Here is a link to the Financial Times article he referenced (you have to do a free trial to the website to read it).

I can’t agree more about the role of strong and capable supervision. At my last manufacturing company, they had long ago pulled out the first line supervisors as “non-value added”, yet another “cost savings” that ends up costing more money I believe. Each manager had at least two departments with at least 30 employees each. As Jon writes, the managers were simply overwhelmed and could not spend enough time on the gemba. They certainly didn’t know their processes well enough to train or coach operators on the process.

As with other factories I’ve seen, if you let a factory run without supervision, you’ll ge the results you deserve. From our lean group, we argued a long time that they needed to add “working team leads” to each department, ala Toyota. They would be the “best” of the operators from each team (someone with the right coaching and problem solving abilities). Management agreed, in general, to the concept and even talked to HR. But, I think cost got in the way.

Strangely though, they added another production manager, so you now had three instead of two (scope of employees went down to about 20). But, for the cost of a manager, they could have added a number of team lead roles (taking existing employees, giving them a pay boost, and then reducing enough NVA work so the team leader didn’t have to run production 100% of the time). But, I think management’s bias is that “management” fixes things, not operators (even under the name of “team lead”). Sad.

Please check out my main blog page at www.leanblog.org

The RSS feed content you are reading is copyrighted by the author, Mark Graban.

, , , on the author’s copyright.


Thanks for reading! I’d love to hear your thoughts. Please scroll down to post a comment. Click here to receive posts via email.


Now Available – The updated, expanded, and revised 3rd Edition of Mark Graban’s Shingo Research Award-Winning Book Lean Hospitals: Improving Quality, Patient Safety, and Employee Engagement. You can buy the book today, including signed copies from the author.

Related Posts Plugin for WordPress, Blogger...
Please consider leaving a comment or sharing this post via social media.

Mark Graban's passion is creating a better, safer, more cost effective healthcare system for patients and better workplaces for all. Mark is a consultant, author, and speaker in the "Lean healthcare" methodology. He is author of the Shingo Award-winning books Lean Hospitals and Healthcare Kaizen, as well as The Executive Guide to Healthcare Kaizen. His most recent project is an eBook titled Practicing Lean that benefits the Louise H. Batz Patient Safety Foundation, where Mark is a board member. Mark is also the VP of Improvement & Innovation Services for the technology company KaiNexus.

Posted in: Uncategorized
Tags:

1 Comment on "Strong Supervision: The Key to Long-term Kaizen"

Trackback | Comments RSS Feed

  1. Bud Bilanich says:

    This is a great post. I agree with you — first level leadership, whether they be team leads or supervisors, are critical to the success of any manufacturing operation. Managers, while not bad people, are usually too far away from the action to be able to make meaningful and timely interventions.

Post a Comment