Archive for the ‘Case Studies’ Category

A Year in the Life of a Production Manager in a Biscuit Factory: Mercy Tshikhase

Thursday, December 10th, 2009

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AT THE START

 

The factory was a shambles.  People were literally sleeping on the job.  Tasks,  which should take an hour, took a day.  The Team Leaders had no sense of urgency and the operators were not committed.  Absenteeism and late coming was poor.  There was control on the line only when the Team Leader was present on the line.  There were Team Leader vacancies with operators in “Acting” Team Leader roles.  Most of the Team Leaders had been “written off” by management as not up to the job.

 

There was no consistency across lines or shifts.  The Team Leaders kept changing.  As Production Manager, she did not know who would be in charge of a line from one shift to another.

  

Changes which made the difference

 

-       The initial Care and Growth training brought clarity regarding the crucial difference between management and leadership.  The Care and Growth model gave her a way to do what she knew intuitively.

 

-       Changes in structure made it possible for the first time to hold people appropriately accountable. This happened when the structure was changed so that operators were dedicated to a line with a Shift Leader for all the operators on each line  A Packing Team Leader was appointed, but each Process Team Leader was accountable overall for the line

 

-       There was an ongoing incremental suspension of control as the Production Manager began to handover specific accountabilities to the Team Leaders A good example of this was accountability for start up on a Monday.  She used to come in early and run around frantically checking that everything was in place for the start up This when she set a clear standard (08h30 start up), provided a Start Up Checklist (a guide only) and required Team Leaders to account for the “why” behind exceptions.  Another example was the chairing of Production morning meetings which used to be done by the Manufacturing Manager.  Now, one of the Team Leaders do it if the Production Manager is not there. The  next step is for operators to chair their own meetings on their line.

 

-       She worked at ensuring that Team Leaders had the support they needed from Support functions like Engineering and Logistics.  According to her: “my Team Leaders only started to believe in me once I made sure that they had the support that they needed to run their lines.”

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The right level/kind of service from Support functions was achieved not by finger pointing/blaming.  She went to Functional Managers with specific issues, eg. no raw materials for Line X, explained the impact it had had on performance, eg. waste due to stopping and starting the line, and then required them  to come back on the “why” behind the specific problem and what they were going to do about it.

 

-       The Manufacturing Manager deliberately ensured that he respected the line of command.  Her standpoint was: “if the Manufacturing Manager changes the plan and communicates this to Team Leaders, then he can’t hold her accountable for the plan.”  The Manufacturing Manager gave her the space to run production.

 

-       She applied the golden rule/value of fairness for any disciplinary action that was taken in Production  The key issue, she believes, is to have the right intent when disciplining.  Her view: “the difficult part is having the courage to initiate discipline, not chairing the enquiry.”

 

-       She focused on “ turning around “ individual Team Leaders who seemed to be hopeless cases.  She did this through a combination of finding out their strengths, understanding their reasons for poor performance and appealing to their sense of pride/believing in them.

 

She was not successful with every Team Leader – an individual was dismissed for poor performance.  She believes, however, that she has killed the perception that “Team Leaders at the factory are useless.”

 

-       She focused on doing what is right/not what the business wanted  from her in terms of results.  She says: “if you do your own investigation and then act on what is right, your people will walk through fire for you.”

 

-       She has committed to lead from the following standpoint:

 

·         Suspend your own agenda/understand that you are accountable to your subordinates, not the other way around.

 

·         Take responsibility for providing the means and ability for your people.

 

·         Have the courage to be fair (there have been four dismissals this year and all have been upheld by the CCMA).

 

-       She put a lot of  emphasis on one-on-ones discussions with each of her team leaders  This, more than anything else, she believes is what builds the relationship and an individual’s confidence/performance.

   

-       She recently established weekly plan/do/review meetings with each Team Leader and their team.  Guidelines were provided by her in the form of an agenda printed on flipchart page (one flipchart per Team Leader for each week in the year).  Her standpoint was: “Keep it simple and make it engaging rather than technically sophisticated.”

 

-       She used the opportunity provided by the Line 7 crisis (OEE – 16%) to demonstrate that the right people (new Team Leader and Operators) doing the right thing, can produce the right result.  (OEE now 97%).

 

 AT THE END OF THE YEAR

 

A credible leadership level (Team Leaders) has been established in the factory replacing the previous lead operators who were Team Leaders in name only.  The results (quality, volumes, speed) have improved accordingly.

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Using an Enterprise Resources Planning System (AX System) to Embed Cultural Change and Leadership Development: Fayruz Abrahams

Thursday, December 3rd, 2009

fayruz_mugshotBackground:

 

During July 2009 a project was launched at Pep Clothing to conclude an Enterprise Resources Planning system implementation that was struggling to become part of the organisation’s culture, over the previous 18 month period.

 

The AX System was intended to integrate various systems and/or components of the business into an integrated system that ensures enhanced work-flow and improves business performance visibility.  This workflow and performance visibility improvements would create a platform that would enable people to enhance their contributions towards PEP Clo’s Vision of Sustainable Growth and Competitiveness.

 

Due to problems that were experienced with the disciplines to consistently follow procedures pertaining to business information, inefficiencies were not visible enough and made the appropriate response to these inefficiencies difficult.

 

After concluding a Supply Chain Team Role Clarification workshop as well as two separate Problem Identification Workshops in different sections of the organisation,  pertaining to the problems that were experienced post the AX system implementation, a variety of problems were identified by employees.

 

The People and Organisation Development Manager in partnership with Schuitema and Associates designed a change management process that endeavoured to implement an effective “process-solution” to capacitate leaders in Pep Clothing to:

a.     Manage the final wrap-up stage of the AX system.

b.    To respond appropriately to the problems that were highlighted by their team members during the above mentioned workshops.

 

The Deliverables for the project were as follows:

 

                      i.    Leaders :

a.     Would be enabled to facilitate change in their areas during the AX Wrap-Up phase and going forward by:

                                          i.    Embedding skills such as problem solving, through the planning and implementation of project plans, supported by coaches who will give the Leaders feedback in real time.

                                         ii.    Training Process Leaders to on an ongoing basis respond to problems that prevent the bedding down of the AX system as they occur and to instil proactive responsiveness.

                                        iii.    Improving their resilience to be able to respond appropriately to the wrap-up of the AX system implementation.

b.    Their roles as Leaders during change were clarified.

c.     Provide the leaders with a framework to enable them:

                                          i.    To empower their teams,

                                         ii.    To cultivate accountability in their end-users.

d.    Commence the Pep Clothing Leadership Development process by integrating the business imperative to implement the ERP system effectively, while leaders would experiment with their newly acquired leadership competencies.

e.     To instil a relationship of trust between the leadership, end users and the information technology system.

 

                     ii.    End-User concerns would be dealt with appropriately by their respective leaders to ensure the following:

a.     Establish information integrity.

b.    Reduce stock adjustments.

c.     Increase employee compliance with AX process disciplines.

d.    Improve the users’ experience of the AX system.

e.     To support Leaders to make the End-Users feel acknowledged and valued by them.

f.     To instil End-User Accountability.

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Key Activities that supported Leaders and End Users with the Change Management Process:

a)     Training:

Key leaders were given a leadership competence platform to provide a common frame of reference for all parties and to inspire them to willingly get involved in the facilitation of the change that was required to implement the system effectively.

b)    The following Leadership Training  took place:

                              i.    Managing Change within the Care and Growth leadership framework.

                             ii.    Course Material: Succeeding as Leaders during time of change. (The Care and Grow Model, Schuitema and Associates)

c)     The following End-user Training took place:

                      i.    Responding to Change (life)

d)    Change was actively managed by leaders in their respective teams/areas as follows:

                      i.    Each Process Leader ran a series of workshops involving their end-users. They facilitated the inputs of the end-users to identify that they experience as well as solutions to the same.

                     ii.    Each Process Leader drew up a Change Management Project Plan for their specific area.

                    iii.    The Project Plan was used at the team workshops to track the progress that was made by the specific team as well as to plan new actions that need to be taken.

                    iv.    The process leaders got in touch with how the end-users experience the system, as well as got to know their team members better.

                     v.    The regular contact sessions during the formal follow-up sessions as well as those that took place in between them facilitated deeper rapport and the building of relationships while the ERP system was being embedded.

                    vi.    The leaders and the process were supported by  two coaches (1 external – Schuitema and Associates, 1 internal – People and Organisational Development Manager). Feedback and guidance was given during and after each follow-up workshop.

                   vii.    The problems that were  experienced were  categorised into one of the following possible root causes, that enabled the leader to decide on appropriate action:

                              i.    Means:

(i)     The barriers in terms of tools, system etc needed to be removed.

                            ii.    Ability :

(i)     Training, coaching or mentoring that may be required.

                           iii.    Accountability:

(i)     In this category all the above was taken care of, and appropriate action needed to be taken against the person who is not performing to standard.

e)     Conversations were structured to assist movement from gripe to goal individually and collectively in workshops. This was part of the theme of holding people accountable for their actions by instilling an understanding of that they are in control of what is happening on the floor and supporting them to take action.

f)      Process leaders demonstrated their leadership (Care and Growth) in a practical and real way, and got to practice the skills that they learned during the training sessions.

g)     A Community of Practice session was held to:

i)     Formally close the project

ii)    Set a foundation for ongoing (in-house) business review of the project and the leadership issues.

iii)     This platform enables continuity of learning culture and beds down the leadership ethos.


 

 Project Evaluation

 

The total possible rating per graph category is 9 (9 respondents to the questionnaires)

Notes:

The score go from +10 to -10…

Any minus score is NEGATIVE – needs improvement/urgent attention

0-5 score means OKAY… but some people are unsure

+5 to +7.5 means good/solid

+7.5 to +10 Great

All scores would have been adjusted by +1 if it had not been for a respondent who only joined the process towards the end and most of her responses were “Don’t Know”

One other respondent also marked many “Don’t Knows”

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         The scoring indicates that in most areas, process leaders are positive and believe significant improvements have manifested.

 

 

The following represent the ongoing concerns:

                      i.    Accurate Financial reporting

                     ii.    Cost control

 

The issues that represent potential problems (in other words, these have not yet been cemented)

                      i.    Proactive planning

                     ii.    Ease of Stock Take

                    iii.    Performance measurements

                    iv.    Downtime reduced

 

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i.    The system has successfully been implemented.

a.     The notable indicator of the extent to which the system – user interface was working is to be found in the Error Log

                  i.    This at the commencement of this project was in excess of 20 000 line item.

                 ii.    Two weeks before conclusion of this project, it had reduced to 300, (4 of which came from the biggest user, Production).

b.    The ERP system was introduced on-time and within-budget, driven by leaders and teams who collaboratively derived solutions to problems – successfully forging an inclusive resolution.

 

 Overall Exceptions:

 

i.    It is evident from the analysis, that leaders still hold reservation about:

a.     SYSTEM: stock adjustments

                  i.    Which indicates that this is an important indicator of ongoing system success and should be incorporated into formal performance scorecards

b.    LEADERSHIP: leaders’ providing real time feedback

                  i.    This indicates, that though they are listening, end-users may still feel unsure while they are waiting for response or update from their leaders.

 

Learning and Insights

 

i.    All leaders appreciated the direct and immediate effect they have, as leaders, on their teams.

ii.    An acceptance of the leaders’ role and responsibility in the issues (barriers to performance) surfaced.

iii.    All issues that hampered the successful implementation of the AX system could be attributed to the variables of empowerment:

a.     I.e. All issues were categorised as being Means, Ability or Accountability issues.

b.    This confirmed that the role leader’s play in ‘unblocking’ the pathways to empowerment of the team is real.

iv.    Leaders realised that paying attention to their people and really listening (with interest and concern) to them – had an exponential effect of the team’s readiness to engage.

v.    The leader sets the limit to the team’s overall capability and willingness.

vi.    Being proactive is crucial – and sets the tone for the leader and team to embrace a more directive role in change:

a.     Moving from victims to masters.

b.    All leaders and teams started to take responsibility for their experiences with the system and became more involved in finding solutions.

c.     This involved a change in attention from what to Get to what to Give.

 

 

 Community of Practice formulated the following:

 

WAY FORWARD FOR Pep Clothing – “EMBRACING CHANGE”

 

On 29 October 2009 Pep Clothing Leadership concluded their first Leadership Community of Practice workshop. The following are the reflections that they shared with the rest of the COP.

 

a)         What was the Difference that made the Difference? Verbatim

 

      i.    I believed that to apply the change, I had to change within myself: what had to change in me: how I thought about change – towards work and personal.  I needed to see myself and my demons. My attitude to change had to change.

     ii.    We were all committed to ONE VISION.

    iii.    We did nothing technical – in order for this to work, no one went to intensive training… it was the approach we had to our clerks and how we nurtured them.  This was the crucial element.

    iv.    To move away from what leaders think others know to what they really know.  We think or wish people can or will do… without first establish it first hand.  Took presumption and assumption out of it. Speaks to intent of leader. 

     v.    To see production moving and succeeding – the exemplars of change (victim to master shift happened with production managers first) this demonstrated well and rolled down to team.  The managers were not just victims.

    vi.    Ownership and accountability – most of change happened in production, from within the individuals (especially the managers)

   vii.    Change happened in me first and the focus was on people from results… now realising that people are important and people realised this.

  viii.    Foundation was provided to all parties in same way (from getters to givers; gripe to goal) this enabled the change.  What happened here (in training session) and the support from process leaders.  The reflection of self – I moved from getter to giver; from hearing to listening.  We grew in this process.

    ix.    Move from unconscious to conscious mode.  Becoming aware of self and the effect on our people was great.

     x.    Focused on people first, and then aligned the people to the process.  Leaders created Purpose and belief: by focusing on people they gave them belief and gave them purpose and this unleashed energy.

    xi.    Alignment that took place throughout business.

   xii.    Mini-reflections enabled growth and understanding.  This enables learning.

  xiii.    Overall: all comments indicate that the shift in leaders’ intent was the difference that made the difference!

 xiv.    Xiii           Adopting the “Victims to Masters” approach (self and team).

  xv.    Ix Always Checking-in with team (regular contact, update, check-ins)

 xvi.    Understanding the Care model.

xvii.    Helping to shift people from seeing only Current reality towards seeing the Future they desired.

xviii.    The employees have a lot of patience, endurance to deal with problems.  Once assisted, recognized, they flourish with ideas and problem solving abilities

 xix.    All team members have evolved into highly capable individuals on AX - we have found some shining stars.

  xx.    My view is different I am more firm, higher expectations with compassion and understanding but less tolerance!

 xxi.    Understand GIVING and HELPING

xxii.    Clear and Specific communication & instructions

xxiii.    Handover of Authority -> Empowerment: Implement monthly reports; budget controls; 1-2-1’s; attend meetings etc. department heads responsible

xxiv.    Reporting function changed

xxv.    Delegation, I’m watching the game as the coach, not team player

xxvi.    We eliminated the ‘blame’ approach

 

b)  What should we continue to do?

 

Standardise the following practises:

 

i.    Workshops on departmental issues.

ii.    Find the solutions.

iii.    Documentation of internal processes.

iv.    Gripe to Goal process.

v.    Support and hold people accountable.

 

c) The Way Forward

 

i.    Build departmental rapport (personal interaction, get to know your people).

ii.    Empower people through training and cross training (look at development needs).

iii.    Have strategic feedback sessions with the different departments; ensuring that people do not feel intimidated. The more complex the terminology or methodology the more intimidated users feel, leaders must find a way of making it accessible.

iv.    Show genuine support and appreciation.

v.    Give everyone a chance to coordinate feedback sessions or KPI meetings.

vi.    Seize the moment: be proactive, not reactive.

vii.    Apply genuine praise.

viii.    Drive improvement through visual progress reporting.

ix.    Develop a KPI format to keep team focused.

x.    Align your dept KPI with rest of business.

xi.    Look at small improvement / continuously.

xii.    Check in – team morale.

 

d) Improvement Focus

 

i.    Look at MY INTENT to grow my people

ii.    Improve my knowledge of coaching

iii.    Be aware of self and your effect on team.

iv.    I am here to serve.

v.    Create a safe and healthy work environment.

vi.    People must work confidently because they want-to, not have-to.

vii.    Leadership development should include:

a.     Leadership enhancement (means, ability, accountability framework); measurable; training on succession planning

 

Conclusion

 

The effectiveness of this change management process over a four month period can be ascribed to:

  • The participants being inspired by higher order aspiration rather than the mere conclusion of a computerised system.
  • Iterative approach with frequent intervals of experimenting, reflection and shared learning and planning the next steps towards concluding the implementation.
  • The leaders and end-users started to recognise the meaning in what they were doing over and above the mere acquisition of better discipline in maintaining information.
  • The AX Bedding Down process became an opportunity for personal growth, for team members to connect around a purpose and for people to exercise their personal growth of intent. “We moved from getters to givers”

 

As people we are meaning making beings and as leaders we need to assist people to deliberately make this meaning to optimise their personal growth and at the same time the business imperative engaged with.

 

Many thanks to all the process leaders who dedicated their energy, time in such an inspired manner to this process. Special mention to, Mark Hobson, Ronel Ellis, Bobby van der Scholtz, Mercia Patience, Arthur Meyer, Johan Southey, Marthie Kemp van der Werf and all the End-Users and specialists involved. Special thanks to Amanda Cronje who both designed and managed the overall change management process.

 

 

 

JM’m Panki Site wins the JM Human Sustainability Award

Saturday, September 12th, 2009

Our client in India, JM’s Panki plant in Kanpur, has won the group’s Human Sustainability Award. This is indeed a major achievement for Panki site. JM Chief Executive Neil Carson said the following about the rewards: ‘With nearly 90 entries from around the group, all of an exceptionally high standard, judging the Sustainability Awards has been no easy task.’

JM Employees at Panki

JM Employees at Panki

  Tarun Ghoshal, General Manager of the site, wrote the following after having won the award:

 

Empowering a Sustainable Workforce

 

A programme of change in work style and behaviour has transformed the Johnson Matthey site at Panki, India. A workplace that was once characterised by a strong sense of ‘them’ and ‘us’ – the worker / management divide – has now become home to a strong team ethic and commitment to excellence. Productivity at work has increased, hand in hand with a greater emphasis on employee and community wellbeing. This remarkable paradigm shift has earned Panki the 2008/09 Sustainability Award for People. The ethos among employees was previously one of only ‘doing what I was asked to’ – and no more. Working structures were inflexible and the site was noted for its militancy. So when the programme of change was introduced there was initial resistance: people were worried about their jobs and felt that any change must be bad.

A Human Resources module called ‘Care & Growth’ was set up to underpin behavioural change. Everyone was covered, from the managers down to the operators on the shopfloor. Individual accountabilities were determined and everyone accepted their roles and responsibilities. This has been backed up by periodic reviews, counselling where needed and a system of performance based pay increases at all levels. In the past, people were more concerned with what they could get, not what they could give, and the site has moved on from a ‘get’ culture to a sense of ‘give to get’.

Formal training needs are identified through an annual assessment and include skills, behaviour and knowledge training which is delivered either internally or externally. To raise awareness of community issues, the Panki site collaborated with the Central Board of Workers Education in a scheme to get involved with the local community and help tackle their domestic health and safety problems. A special training module on CSR was devised for Panki employees.

A morning meeting is held at the start of every working day, with everyone attending. A calm tone is set by a few moments of yoga and then the operators themselves lead the meeting. The performance of the previous day is discussed, together with the plan for the coming day. The nitty gritty questions of production are covered and tricky issues of incidents, near misses and absenteeism can be raised in a blame-free atmosphere.

Self confidence has soared as operators have begun to take responsibility for their machines and their jobs. So too, has productivity up 37% and 50% at the two plants; while the production of catalyst pellets per man hour has increased by 141%. 

This is altogether a happier workforce where people think in terms of ‘my factory’ and where there has been no disciplinary action for over two years. The health and safety record is robust. With a greater understanding of life, work and the economy, people at Panki are on the road to a sustainable culture of work excellence and selfless giving.

Care and Growth at JM by Chris Walker

Tuesday, September 8th, 2009
JM Clitheroe

JM Clitheroe

As an overall organisation we didn’t embrace the model from day one (the reality is that we have been at it for ten years now). The site manager at Clitheroe heard about it and then a couple of us who were also based at the site got interested and decided we would do it ourselves. Interestingly, the values and beliefs of the management team at site at the time probably made it easier to introduce the model. However, as with all change the leadership resisted until they grasped and understood the principles (just like any other change process).
 
What didn’t happen at Clitheroe, that in my own experience happened many times with other ICI initiatives, was that the leadership team who saw the benefits of the idea, didn’t cave in to pressure. They continued the journey albeit at times a difficult one (the battle was still uphill) - they were resolute!
 
Often the old ICI culture was institutionalised and this made it easy for managers to just opt out of anything they didn’t initially like. There was no pain if they didn’t move forwards. When there was pain it didn’t last for long (”there would be another initiative along soon”). There was little pleasure for those who did adopt change and not much building on successes by the senior team - the ICI culture lacked accountability in the truest sense!
 
Clitheroe provided a unique opportunity for implementation in that it was largely isolated from the rest of what was then ICI (I guess we took it out of the worst parts of the institution). To a large extent it was the pilot for the rest of the business without any real intent for it to be that way. It was done because it was the appropriate thing to do.
 
The Clitheroe site needed to change and care and growth was one of the vehicles that helped. The site was small enough that the senior team new every individual by name, there were personal relationships that enabled the infiltration of the care and growth programme across the site to be done more effectively. It’s taking a long time and Im pretty sure that’s a good thing (heaven forbid we ever stop working at it).
 
The organisation as a whole came along more slowly and steadily and care and growth wasn’t introduced to the wider organisation with a fanfare. In reality true movement began about four years later. Some of the senior managers at Billingham embraced it because it appealed to their values but for others it has been a similar experience to that of Clitheroe - hard and long.
 
The organisation has moved significantly in implementation of the priciples and in utilising them but we have a way to go before it “really” is the way we do things here. What is heartening is that the senior team are resolute in their support even when they find it difficult.
 
The model in itself in fascinating in that it gives a simple language that everyone from an operator to an MD can understand and engage with. I cant think of any other leadership model that I have engaged with that speaks to all manner of men “its not consultant speak”, it gets to the heart of what being a human is all about (most of the models I remember confused the trainers, let alone the people who were supposed to live and breath the stuff afterward)
 
What is interesting is that universally people cannot and do not argue with the principles that sit behind this model “a leaders job is to give means, ability and hold people appropriately accountable;” - this is unique in my 30 years experience. They don’t necessarily find it easy to live it and breath it every day but they are working at it and that’s as much as can be expected (our role now is to enable them)
 
Final thoughts for now would be to reflect on my personal experience of Schuitema, care and growth et al and to say that although simple in its appearance, the use and embracing of what it is really all about is infinitely complex and yet at the same time infinitely simple! “Do what you can for others and but more importantly do what you can for yourself”