Joyful day in manufacturing – is it possible?

Problem solving in organization:Challenges that apear during the process

Just imagine a day when you don‘t

need to:

- “run” from one meeting to another,

- take care of problems in

manufacturingand you sit leisurely in your office.

– no urgent calls,

– employees don’t come in every five

minutes to inform about new problems...

Seems like something unreal like from

fairytale?

Reality

Yes...

Today PEACE is a

RARE phenomenon in

manufacturing.

A calm day without any worries only a fantastic vision

that is very far from reality...

becomes

Common problem solving

One person solves a lot of problems, for example: • How to increase productivity of

machine Z?• How to reduce changeover time?• What strategy to use in negotiation

with customer?and lots of similar.

Common problem solving = Fires

We solve the problem

which “is burning” the

hottest.

How to avoid spelled circle of fighting the same fires

and eliminate the core cause from the beginning?

Common problem solving = Fires

When manager is forced to solve all problems by himself

Common problem solving = Fires

When manager is forced to solve all problems by himself

Alternative problem solving = Eliminating the firesWhen the middle and entry-level staff is involved

Production

manager

Supervisor

Operator

Operator

Supervisor

Operator

Operator Production

manager

Why operators and supervisors?

• Operator operates the machine every day and he knows

how everything works the best.

• Operator will implement the vision for real. And if he

sees the vision he can say what needs to be changed..

• Supervisor can go to operators’ work center more often

to make sure that the core cause is eliminated.

Alternative problem solving = Eliminating the firesWhen the middle and entry-level staff is involved

Production

manager

Supervisor

Operator

Operator

Supervisor

Operator

Operator Production

manager

Why involving more hands into the process is necessary?

„The most of my work day I spend solving problems“-

say 98 % of managers

So how to find some

time for solving

strategic or business

development tasks?

Manager has to spend a lot of his time for daily

problem solving so we tried to identify cause and

effect relation using 5 Whys methodology.

#1

Why you spend most of your daily work time solving problems?

#1

Why you spend most of your daily work time solving problems?

Because I need to solve many, repetitive problems at

the same time.

#2

Why you have to solve repetitive problems every day?

#1 Why you spend most of your daily work time solving problems?

Because I need to solve many, repetitive problems at the same time.

#2

Why you have to solve repetitive problems every day?

Because employees fail to implement made decisions

properly and it needs to be solved again.

#3

Why employees fail to implement made decisions properly?

#2 Why you have to solve repetitive problems every day?

Because employees fail to implement made decisions and it need to be solved again.

#3

Why employees fail to implement made decisions properly?

Because they always do it in the wrong way and they

don’t get required result.

#4

Why employees don’t get the required result?

#3 Why employees fail to implement made decisions properly?

Because they always do it in the wrong way and they don’t get required result.

.

#4

Why employees don’t get the required result?

Because they don’t understand the exact principles of

final result.

#5

Why employee doesn’t understand the exact principles of result?

#4 Why employees don’t get the required result?

Because they don’t understand the exact principles of final result.

#5

Why employee doesn’t understand the exact principles of result?

Because he doesn't see the final result as I imagined it.

#6

Why employee doesn’t see the final result as you imagined it?

#5 Why employee doesn’t understand the exact principles of result?

Because he doesn't see the final result as I imagined it.

#6

Why employee doesn’t see the final result as you imagined it?

Because I made the decision and I know how it should

look like.

How often it all works right from the first time?

99/100

Failure

99/100

Failure

Only after you start implementing

experiment, you can see that there is

something that needs to be changed...

1/100

Success

Can a person who doesn’t know how the

solution of problem looks like,

understand that to reach it he needs other

solution?

1/100

Success

1/100

Success

Or maybe it is possible to make that

employee would find problem’s solution

by himself?

That is how employees’ empowerment is understand

Supervisor, OperatorManager

WHAT

and HOW

to do

WHAT

and HOW

to do

That is how employees’ empowerment is understand

Supervisor, OperatorManager

WHAT

and HOW

to do

WHAT

and HOW

to do

While delegating the task to employee manager says

what and how to do but the explanation why it is

needed to be done is missing. In such case employee

works like a robot – does what he was told to do.

But he doesn’t think through what can be done

differently?

That is how employees’ empowerment should look like

Supervisor

WHAT and HOW

Supervisor, Operator

That is how employees’ empowerment should look like

Supervisor

WHAT and HOW

Supervisor, Operator

If we want that employee would start searching for

problem’s solution we need to give him WHY. After he’ll

understand WHY it is important to eliminate the

problem he’ll see the possible solution and will start

searching ways how to solve the problem by himself.

Knowing why, he’ll find out how and what to do by

himself.

Employees’ empowerment

WHAT

and HOW

to do

WHAT and HOW

How people are solving

problems in Your

organization?

Thank you for your attention!

More about employees’ empowerment tools

we’ll share in two weeks.

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