Best Practices For Operational Excellence
Best Practices For Operational Excellence
Best Practices For Operational Excellence
Luca Dellanna
@DellAnnaLuca
Luca-dellanna.com
First edition
December 2019
OUTLINE
This book is divided into three parts.
In the first part, you will learn the Four Principles of Operational Excellence to be leveraged in order to create
an Operational Culture worth working in.
In the second part, I will detail the Eight Best Practices to transform the Four Principles into visible actions,
which you can carry out starting today in your organization. I will provide detailed lists of steps and comprehensive
examples to facilitate their execution.
In the third part, I will provide you with a roadmap for planning a plant-wide or company-wide change
initiative, for achieving Top Management buy-in, for its effective roll-out and for its long-term sustenance.
But first, let’s take a look at the importance of Operational Excellence and at the costs of a mediocre Operational
Culture.
A MAP
When you look at a map describing the roads in your city, you do not see every single building and every single tree.
Not describing the full territory is not a defect of maps, but a feature. By leaving out some details, they allow the
reader to focus on the information present and to take effective action.
Similarly, this book does not pretend to explain everything there is to know about Operational Excellence – it would
take a hundred books to do so. Rather, this book describes most of what you need to know in order to be able to take
effective action to improve the Operational Culture of your team.
If you have any question whose answer is not contained in this book, you can always drop me a short[3] email at the
contact listed in the author section at the end of this book.
TERMINOLOGY
In this book, I use the following definitions for roles: “Worker” refers to any employee who does not manage any
subordinate, “Supervisor” refers to any employee who manages workers, “Manager” refers to any employee who
manages subordinates of any kind (workers, supervisors or other managers) and “Top Management” refers to the
CEO and other top executives such as C-suites and Vice-Presidents.
Unless specified otherwise, by “subordinates” I intend those who report directly to person being referred to. For
example, “your subordinates” would include your direct reports, but not your reports’ reports, if any.
DISCLAIMER
The contents of this book consist in the learnings the author made based on his experience. While he genuinely
thinks that this book should help most of its readers, its contents are highly contextual. Only you know what’s best
for you. Always use your common sense and reach out to experts whenever appropriate. None of what is written in
this book is to be considered medical advice, financial advice, investment advice, or advice of any other kind. The
author shall not be held liable for the consequences of the application or misapplication of the contents of this book.
The Costs of Lacking Operational Excellence
Achieving and maintaining a great Operational Culture costs time and money. However, such investments are cheap
compared to the costs of a mediocre Operational Culture, plagued by structural problems, demotivated employees
and lack of clarity and trust.
Let’s first see the costs for managers like you.
Overtime: in companies with mediocre Operational Culture, action is slow and problems aren’t
addressed without constant attention by the manager. In companies with great Operational Culture,
instead, there is no need for micromanagement, and managers are more likely to (and are encouraged
to) leave their work on time most of their days.
Lower bonuses: teams with mediocre Operational Culture fail to achieve their business goals or
bring minimum impact to the bottom line. Instead, teams with great Operational Culture effectively
contribute to the success of the company, which has then the funds and the reasons to distribute large
bonuses or raises.
More stress: it is stressful to work in a team with mediocre Operational Culture, where new and old
problems surface every day. Instead, teams with great Operational Culture take care of problems
once and for all, allowing their members to work in an environment mostly deprived of toxic stress.
Less energy: managers of teams with mediocre Operational Culture spend their days “putting out
fires”, running from one place to another solving urgent problems, an activity which would quickly
deplete anyone’s reserves of energy. Instead, in teams with great Operational Culture, problems are
solved by individual team members, leaving the manager free to work on a few important problems
rather than on many urgent ones.
Less trust: in teams with mediocre Operational Culture, career advancements are based at least
partially on factors other than results. Behaviors such as servility, adulation and backstabbing go
unpunished at best and are rewarded at worst, creating an environment where it is impossible to trust
most colleagues. Conversely, in teams with great Operational Excellence, people are rewarded to act
in accordance to Core Values and objectives – both defined in objective terms – and punished if they
exhibit any toxic behavior. The result is an environment where everyone can trust each other.
Less satisfaction: for all the reasons above, to work in a team with mediocre Operational Culture is
consuming, tiring, stressing, and not worth it financially. Instead, working for a team with great
Operational Culture is rewarding, both from the financial and the mental point of view.
Just like a mediocre Operational Culture is bad for managers, it is also expensive for companies. These are the direct
costs of lacking Operational Excellence:
Defects, which lead to scrap, rework, customer support and recalls.
Poor logistics, which lead to transportation, storage and capital immobilization costs which do not
add any value to the customer.
Injuries, which lead to stopped production and worker benefits.
Environmental problems, which lead to fines.
Unethical workplaces, which lead to fines, rogue employees and key personnel being fired for
ethical violations.
These direct costs are dwarfed by indirect ones:
Defects lead to brand issues, making it more expensive to acquire and retain customers.
Poor logistics lead to stopped production in case of delays in the supply line, in unhappy customers
or in customers having to source another supplier (a competitor of yours) to protect themselves from
your delays.
Injuries lead to poorer quality and operations (as less experienced workers have to substitute for
injured ones), lower morale and higher insurance costs.
Environmental problems lead to brand incidents (damaging the image customers and potential hires
have of the company) and risk of losing the permit to operate.
Unethical workplaces lead to brand incidents, difficulties in hiring and retaining talent (most people
do not want to work for a company with a poor work environment and must be overpaid to do so).
Poor management leads to employees having a lower morale and motivation, underperforming in all
other areas, and key employees leaving the company.
Summing it up, companies with poor Operational Culture lose their good employees (to injuries, burnouts,
competitors) and remain with bad employees only (low-talent or unethical ones), which further lowers the
Operational Culture, creating a vicious circle from which it is difficult to exit.
For all the reasons listed above, it is beneficial both to managers and companies to strive to implement Operational
Excellence in their organization.
Let’s see how.
Managing difficult employees
Before entering the core of this book and describe the Four Principles of Operational Excellence and the Eight Best
Practices to implement them in your organization, let’s explore three problems most managers like you face:
managing difficult employees, getting the time to do everything and creating an environment of trust. They’re not an
exhaustive list of course – there are more urgent and more important problems – but these are the three problems
which will be covered as the introduction to the core of this book: the Four Principles of Operational Excellence.
By “difficult employees”, I refer to those who appear to chronically lack any motivation, to those who seem to resist
any attempt to change their ways of working, to those who have adversarial reactions to attempts to train them, or to
those who lack the discipline required to work in a team.
The reason why these four seemingly different groups are classified under the same umbrella is that they have a
common root cause: the employee does not know that good individual outcomes follow achieving objectives (or he
forgot about it, or got taught otherwise by working under bad managers, or believes that it is not true in your
company or under your management).
In some cases, the employee never got to learn the link between achieving objectives and good individual outcomes
because he has always lacked the skills to do the former or because he only encountered teachers and managers in
his life who never rewarded him with the latter. In other cases, the employee happened to spend the last months or
years working for a manager who failed to set any attainable objective, or who failed to provide him with the skills
and supports required to achieve it, or who was inconsistent in rewarding him for having achieved his objectives, to
the point that the employee forgot that achieving objectives is followed by good individual outcomes.
In a few cases, the root cause is instead that the employee did not get to learn the link between doing something bad
and bad individual outcomes. This happens when the employee, for any reason – at work, or in his early years at
school – did something which was bad, did not get punished and reaped benefits instead. For example, the employee
might have been arriving late at meetings and experienced no material consequence, thus learning that bad behavior
goes unpunished.
In rare cases, there are other reasons underlying underperformance or bad behaviors, but the reasons listed above
cover the large majority.
Difficult employees behave as such because they experienced a paradigm where bad behavior is more
advantageous than productive behavior.
The solution, therefore, is simple (though hard): the manager should let them experience a different paradigm, where
bad behavior consistently leads to negative individual outcomes and good behavior consistently leads to positive
individual outcomes.
The key word is consistently. It’s not that most managers do not reward achieving objectives. They do.
However, often, they do it less consistently that they let having achieved objectives go unrewarded.
Unfortunately, people are more likely to remember that one time where their efforts went to waste rather than those
nine times where they got rewarded. Unless the manager is obsessively consistent in making sure that the
consequences he promises (both good and bad) take place, his words will not command attention. Inconsistent
managers debase their authority. Respect, trust, and authority are all gained by being consistent, and one single
moment of inconsistency might ruin months of consistency and create motivational losses.
Many managers feel like they do not have the time and resources to be fully consistent in rewarding their
employees. The next chapter, “Getting the time to do everything”, will address this issue.
When facing an indifferent subordinate, the manager should teach him again that good outcomes follow good
performance and that such good performance is attainable for him. The manager does not need to teach a
demotivated subordinate to produce results; he needs to teach him that producing results brings good individual
outcomes. These are two completely different concepts, and a manager focusing his efforts on the former while the
bottleneck is the latter is setting himself up for frustration.
(Of course, in case skills are the factor limiting the performance of the subordinate, and not motivation, then the
manager will have to focus on ensuring he gets the required know-how.)
MOTIVATIONAL LOSSES
Every time an employee thinks he achieved an objective but does not get rewarded appropriately, he suffers a
motivational loss.
Some employees are more internally motivated and can withstand a few motivational losses without being affected
in their day-to-day, but any employee has a “breaking point” where, after enough motivational losses, he will lose all
enthusiasm and become a difficult employee or quit the company.
It is therefore extremely important that managers avoid any form of motivational loss in their subordinates, and this
includes avoiding ambiguous objectives.
If the objective assigned to a subordinate is not clear, then it is possible that the subordinate equivocates and
produces a work which he genuinely believes achieved the result he was tasked with. In this case, when the manager
will have to tell him that his work was not good enough, the subordinate will suffer a great motivational loss: he
expected a praise and received a reprimand instead.
Unambiguous objectives are necessary to avoid motivational losses (this concept will be the topic of the First
Principle of Operational Excellence).
TOXIC EMPLOYEES
The above notwithstanding, some employees are not just “difficult”. They are toxic. Whereas difficult employees
just forgot (or never learned) the relationship between fulfilling objectives and good outcomes, toxic employees
operate from a different set of beliefs and paradigms that are destructive to the Operational Culture of the team.
Whereas difficult employees should be treated as potential assets and trained so that they become one, toxic ones
should be treated as liabilities, and action should be taken to let them go, if allowed by the local legislation.
In my experience, companies both overestimate the percentage of toxic employees (most are just difficult ones) and
underestimate the need of letting them go as fast as possible, if allowed.
Firing toxic employees might seem cruel, but keeping them in is more cruel: to their colleagues (whose efforts
become devaluated), to the company (whose situation becomes harder, as it is burdened by the toxic employee) and
to the employee itself (who could benefit for a change of environment or from a strong signal that his behavior has
to change for good things to happen for him). Of course, firing should be a last recourse solution after having
competently and wholeheartedly given him chances to change his behavior and support towards it, to validate the
hypothesis that his toxicity is an inherent part of who he currently is and not a temporary reaction to an unconducive
environment.
SUMMARY
If you have difficult employees, you need to get them to experience the link between fulfilling objectives and good
personal outcomes.
1) Give them achievable objectives.
2) Catch them doing something right, such as fulfilling objectives or following rules.
3) If they do so, thank or praise them appropriately, then raise the bar – but not too much.
4) If they do not, lower the bar and try again – but not too much.
Getting the time to do everything
As a manager, you will most likely be haunted by days with too much to do and too little time.
For many managers, the reaction is working longer hours. This might be needed in case of exceptional deadlines,
such as the last days of the year, but is never a good idea when its application is too frequent – more than 6-8 weeks
per year. Chronic overtime brings stress and jadedness, both of which increase the risk of mistakes and limit the
professional growth of the manager.
Moreover, whereas in companies with poor Operational Excellence working overtime signals commitment, in
companies with good Operational Excellence it signals structural problems such as the inability to prioritize
effectively and get stuff done.
I once overheard an executive saying that he could not promote that employee who was working long hours because,
if he did, the employee would find himself with too many responsibilities to juggle and would either have to
increment his working hours to the point of a burnout, or inevitably “let some ball drop” and underperform.
(Imagine the shock if the employee learnt that – he thought that working long hours would help his career!)
Let me be clear: it is not working overtime which is bad. In small doses, it is good. It is systematically working
overtime which is bad. The former represents taking care of unusual spikes in workload, whereas the latter
represents working overtime to take care of the usual workload – an indicator of a structural problem.
Being understaffed might be the temporary reason for a chronically high workload, but it is never the long-term
reason. A good organization which finds itself understaffed – due to the sudden leave of a few employees or due to a
sudden increase in business – would quickly react and hire the missing talent. If it doesn’t, it might be for three
reasons: the Top Management is not competent or committed enough, the business is horrible (your company
operates in a shrinking or unprofitable market), or managers are not good at prioritizing. If one of the first two cases
applies to your organization – consider changing company, to avoid fighting an uphill battle. If instead your case is
the third one – bad prioritization – the rest of this chapter will be useful to you.
A GOOD QUESTION
If you keep spending your workdays like you’ve been doing recently, how will the Operational Culture of your team
look like in a couple of years?
How will your work life look like?
AN INTRODUCTION
The content above is just an introduction to the topic of personal productivity and on the actions you should be
taking as a manager. You will find more practical content in the core of this book.
ACTION POINT
Make a list of recurring problems which are consuming your time and select the one which is consuming the most.
Is there any action you can take today to reduce future wastes of time originating from that problem? Can you
address its root cause?
Creating trust
As a manager, you want to have the trust of your subordinates. They will share more information with you, they will
escalate problems sooner when needed – allowing you to tackle them before they become too big – and they will
work on the objectives you assign them faster and better, without questioning them.
However, trust is not a given; it must be earned. Below are some requirements for trust and how to achieve them.
Competence: your subordinates will not trust your decisions if they do not believe you are competent at your job.
Three factors will influence the perception of your competence: your background (have you been working in the
field for long enough? Do you have previous experience in Operations?), your achievements (did you achieve great
results in the past? Did the teams you manage achieve great results?), and whether you listen to your subordinates
and explain your decisions to them.
You might have limited influence today on the first two points – background and achievements – but you can work
on the third one. As a manager, you have a privileged point of view of the business, having access to much broader
information than your subordinates. Therefore, you might “know better”. However, if you take decisions without
listening to your subordinates nor explaining to them the reasons for which you took such decisions, they might not
trust that you do indeed “know better”.
Often, your subordinates will not agree on your decisions. However, if you gave them reasons to believe you
genuinely listened to their full point of view, even if you end up taking a decision they disagree with, they will not
resent you for it – at least not in the long term. Instead, if they are on the impression that you did not listen to them
fully – regardless of whether you actually did – taking a decision they do not agree with will be perceived as
incompetence and cause a break of trust.
In later chapters of this book, I will describe a few Best Practices which are designed to ensure that your
subordinates feel listened to and trust your decisions.
Visibility: your subordinates will not trust your decisions if they do not believe you are at least somehow
knowledgeable about their job. This requires you to spend at least part of your time at your subordinate’s floor, at
their desks, with their teams. If you only meet them in your office or in conference rooms, they will have the
impression that you do not really know what’s going on in their work life – regardless of whether this is actually the
case.
In a later chapter of this book, I will describe a Best Practice, “Management Walks”, which is designed to address
this point.
Fairness: as a manager, you should strive to enforce rules and evaluate people in a fair way which is predictable and
identical for all. No favorites, no exceptions, no “judging the effort” or “excusing the circumstances”. Judging
everyone equally will prevent them from thinking that your decisions are personal. If, instead, you use double
standards or subjective judgements, your subordinates will have the possibility to think you are making it personal
and they will trust you less.
Principled: counterintuitively, people cannot fully trust someone who is loyal to individuals. What if he will have to
decide between two people he swore loyalty to? People only trust those whose behavior they can predict[4], and the
behavior of those who are loyal to individuals is fickle. Instead, people who are loyal to principles are fully
predictable and therefore can be fully trusted.
If you consistently act and objectively evaluate people based on fair principles which are conspicuously known and
do not change over time (so, no surprises nor lunaticity), your subordinates will be able to fully trust you. They will
be able to predict how you will react to their actions. They will know that, if they come to you confessing a good
faith mistake, you will not think less of them and will react appropriately. They will be more open with you and,
eventually, will begin acting according to your principles too.
The most important task of a manager is performance management: setting objectives for his subordinates and
holding them accountable for their results. Performance management impacts both the short-term performance of the
team (directing and motivating the subordinates on their current tasks) and its long-term performance (powerfully
communicating values and standards by rewarding desired behaviors and punishing undesired ones).
When a manager fails to execute on performance management, he compromises the good results he might
have obtained in other areas, such as communication, hiring and decision making. Skillful managers will still find
themselves with an underperforming team, if they did not demonstrate to them that individual outcomes consistently
follow individual performance on the objectives they have been given and on living the Core Values of the
company.
Many managers have trouble with consistently holding their subordinates accountable in a fair and constructive way.
Some are uncomfortable with telling their underperforming subordinates that they did a bad job, especially when it
could be argued that “they did what they could”. Others fail to consistently reward the good performance of their
employees, because they lack the budget or time to do so. And some fail to be fair in their evaluations, because they
were not clear in how performance was to be evaluated or because they considered factors other than performance.
There is one common trait shared by managers who have trouble with consistently holding their subordinates
accountable: they do not set clear objectives. This is the cause of most of their problems with regards to performance
management.
Most managers understand the importance of the points above, but fail to consistently apply them in practice, for 6
reasons:
Objective Cause Explanation
is…
Ambiguous The manager is The manager does not know
incompetent. how to set clear objectives or
why it is important to do so.
Ambiguous The manager wants The blurrier the objectives, the
to retain political more the manager can be
power. subjective in his rewarding and
thus draw power from his
ability to apply such
subjectivity.
Ambiguous The manager is The blurrier the objectives, the
afraid that he won’t easier for the manager to
be able to follow-up confabulate a reason for which
with rewards or consequences should not follow
punishments. results or lack thereof.
Ambiguous The manager is The blurrier the objectives, the
afraid that the team easier for the manager to justify
will not be able to to his boss why his team
produce satisfying underperformed but neither him
results anyway. nor individual members should
be hold accountable.
Collective The manager dreads The manager assigns
having any difficult responsibilities to groups only,
conversation with so that individual responsibility
individual is unclear and cannot be
subordinates. rewarded nor punished. This
does not mean that good
managers do not use group
objectives but that doing so is
not sufficient; it is necessary to
also use individual ones.
Unrewardable The manager does Objectives should not be set so
not respect the that they are comfortable, but
capacities of his so that good things happen if
subordinates or his they are achieved.
own ones and ends
up assigning too
conservative
objectives.
In all but one of the rows above, when managers fail to set clear objectives it is not because of a lack of skills.
Rather, it is because of some mental patterns of theirs that makes them believe that setting unclear objectives
is the optimal choice.
One particular instance of this phenomenon is the vicious circle of bad management, described below.
LACK OF MOTIVATION
When good managers spot a lack of motivation in their subordinates, they interpret it as a signal of a lack of clarity.
Such lack of clarity might be of 3 kinds:
- Lack of clarity of objectives: because the objectives are not clear, the subordinate is confused about what has to
be done next. This undecidedness is often mistaken as a lack of motivation.
- Lack of clarity of personal impact: because the objectives are not individual, the subordinate is unsure about the
scope and importance of his personal impact and is less motivated towards taking effective action. Maybe, he waits
for someone else in the team to take action. Or perhaps, he doesn’t want to risk overstepping on someone else.
Either way, he doesn’t act proactively nor wholeheartedly.
- Lack of clarity of individual outcomes: because the objectives are not linked to clear individual outcomes
dependent upon individual performance, the subordinate is not motivated to act outside of his comfort zone.
In his book “High Output Management”, former Intel CEO Andy Grove shares the following allegory for
delegation. Imagine having to delegate to a subordinate of yours the task of writing his name on a piece of paper.
You tell him what is requested from him and hand him a pencil. However, you do not release your grip on the
pencil. Your subordinate struggles to write the first letter: your holding onto the pen prevents him from moving his
hand. You recognize the difficulty, and you offer to help. As he moves his hand to write the second letter, you try to
help by guiding the pen. The result is a mess.
Your subordinates cannot do what is required from them unless, after you provide them with the tools, you
release your grip on them.
With this allegory, let me introduce the topic of delegation.
DELEGATION
When delegating a task, a manager can either prescribe the result or the method. For example, he can ask an
employee to fix a broken machine (the result) or he can ask him to change that broken component on the machine
(the method).
The difference is that in the latter case, if the broken component is changed but the machine still doesn’t work or
malfunctions again shortly after, technically, the employee completed his task. This is problematic, because it will
result either in the employee ending up frustrated for having been told his job was not good enough even though he
did what was requested from him, or in the employee being “trained” to ignore the results which matter (in this case,
whether the machine works properly).
If an employees’ task is to apply a method, he will have to apply it, even if he knows that the method is not
appropriate to the situation at hand and even if he believes that the method will not be helpful in the long term.
Instead, if an employee’s task is to achieve a result, he will choose the most appropriate method and, in case that
would not reach a satisfactory result, he will try another one until the task is completed. Especially if he had
evidence from the past that he will be held accountable, both in positive and in negative terms, for the ultimate result
of his task.
Prescribing methods removes accountability, whereas prescribing results enable it.
Assigning problems to solve (rather than tasks to complete) is a great way to ask for results without prescribing
methods.
LOCAL KNOWLEDGE
In general, a manager will have more knowledge regarding what results are needed by the company, whereas an
experienced line worker will have more knowledge about how to achieve such results. This is because of the
different kind of information each of them is exposed in their day-to-day work: the manager spends a sizable amount
of his time participating to meetings and reading reports, whereas the line worker spends most of his time
completing hands-on tasks.
This is not a problem when neither role oversteps the other one and everyone does what they know best. The
manager, who is responsible for setting objectives, has a better overview of what the company needs; the line
worker, who is responsible for completing objectives, has a better knowledge of what to practically do to achieve
them.
However, in some cases, the manager might know better than the line worker how to achieve the objectives. This is
the case of a newly hired line worker who is still undergoing training or of a newly promoted manager who used to
do the work of the employees he now manages.
In such cases, the manager has to be careful not to use his superior knowledge to prescribe instruction, for two
reasons.
First, the more the manager exploits his superior knowledge to assign instructions together with objectives, the more
restricted the perception of a role will his subordinates assume[7]. The subordinates will come to believe that their
role is to follow instructions rather than to achieve objectives. This will become a problem unless the job of the
subordinates entirely consists in following a list of instructions with no chance for variations or incidents to take
place (almost no job is like that).
Second, it is very rare that the manager knows the environment in which his subordinates work. Most often, they
know the environment in which they themselves used to work when they were in their subordinate’s position. In
industries in which processes and technologies change very fast, a manager who thinks he knows the job of
his subordinates quickly becomes a hindrance to the performance of his team, preventing its members to adopt
new approaches and new tools. The faster the rate of change in an industry, the more the manager must assume he
doesn’t know (anymore) how his subordinates should complete their tasks.[8]
This does not mean that a manager should always let his subordinates figure out it entirely by themselves. He can
figure it out with them, but he should never figure it out for them.
If I had to summarize this chapter in a single sentence, it would be: do not do anything which might decrease the
accountability of your subordinates.
THE LOWEST COMPETENT LEVEL
Good companies acknowledge that, whereas objectives have to be set from some level of overview, the decisions
related to how to complete them are complex and require specific, fast-changing, low-level local knowledge.
Therefore, great companies strive to have decisions taken at the lowest competent level.
For example, they know that in supermarkets the local store manager should be the person who decides which
products to shelf[9]. Not (only) because empowering him would motivate him and would make him grow, but
because he is the best-placed person to take that decision. He is the one who best knows how his customers behave
and how a change would affect the complex processes in which he spends his day-to-day. The person in the highest
position might have access to more information, but this is a reason to give access to such information at a lower
level, not to take decisions at the higher level.
This does not mean that the lowest competent level’s decision should not be vetted by higher levels before being
executed; in some cases, this is necessary to prevent mistakes which might endanger the company.
Similarly, this does not mean that the lowest competent level necessarily coincides with the lowest level (regardless
of competence). In the example above, the decision on which products to shelf can perhaps be taken by the local
store manager, but not by the newly hired cashier.
Too often, companies take decisions at the highest competent level instead. Sometimes, this is due to the ego of the
executives involved. Other times, it is due to a genuine yet incorrect belief that competence is correlated with rank
for any kind of decision.
In general, the rule of thumb is: decisions on what objectives to pursue should be set at the highest competent level
and then trickled down. Decisions on how to fulfill the objectives, instead, should be taken at the lowest competent
level.
NEGOTIATING OBJECTIVES
One common problem I noticed afflicting most young project managers is a deep-rooted belief of efficiency being
superior to efficacy. This is true for student life (often, students are constrained in their resources and try to “make
the most of what they have”), but it is not always true for companies, for which “achieving results no matter the
cost” is often more important.
Don’t get me wrong: efficiency is very important for companies too, but there are situations – such as winning a
huge contract or satisfying a critical customer – where efficacy trumps efficiency, and Top Management would be
much more satisfied with a “I achieved 100% of the objective spending120% of the budget” than with a “I achieved
80% of the objective with 50% of the budget”. In my experience, young employees are particularly susceptible to
encounter difficulties in internalizing this.
To avoid situations like the one above, great managers teach their subordinates how to negotiate objectives. They
explain to them that, if they have too much on their plate, they should be the one raising the hand and saying, “I
have too much on my plate and cannot do everything well, what should I prioritize?”
Seasoned managers know that this is very preferable compared to trying to achieve everything and then failing, as
the latter might catch everyone off-guard and start a chain of negative events. Young employees do not know this
and must be taught it.
Similarly, objectives can be negotiated regarding budget, internal support, external support, training, etc. The only
thing which cannot be negotiated, especially after it’s too late, is the desired outcome.
SUMMARY
When delegating, make sure your subordinates understand that they will be held accountable for their result on their
objectives, no matter what might happen.
Avoid any behavior which might introduce ambiguity on whether they will be judged for their result on their
objectives.
The 3rd Principle
of Operational Excellence:
Most companies genuinely want their Core Values, such as sustainability, safety, or respect for people, to be a
reality. However, too often, the day-to-day behavior of their employees fails to embody them.
In this chapter, I will describe the one thing that great managers do to faultlessly get their subordinates to internalize
the Core Values of their company.
PLAUSIBILITY
Not all workers think that Core Values are costs to minimize. Some genuinely believe in them. However, believing
in a Core Value is not enough to practice it. A worker has to know that his manager practices it as well. In other
words, he needs to know that he won’t be reprimanded by his manager for having incurred the short-term costs of
having practiced the Core Value.
The only way to know this with certainty, is by seeing his superior incurring such costs himself. This provides the
worker with the plausibility to say: “Yes, I’m costing the company by embracing Safety, but my superior is doing
the same. I’m following his example.” He will not fear being held accountable for having incurred a cost.
Words can be misinterpreted (“I didn’t really mean this”), actions cannot. Because they are visible and material, they
are conspicuous. And, because they are conspicuous, they become norms.
A good manager who spends some of his precious time to follow safety procedures sends a clear message: “You
won’t be punished for doing the same.”
A bad manager who instead skips safety procedures sends another message, just as clear as the previous one: “I only
allocate my precious time towards actions that contribute directly to the bottom line, and you are expected to do the
same.”
COST AS A SIGNAL
The costlier an action, the stronger the signal it sends. Diamonds are an effective signal of commitment precisely
because they are costly.
Bad managers use words to communicate Core Values. Words are cheap, and their effect is limited.
Good managers use both words and actions. The costlier the action, the stronger its effect towards getting
Core Values internalized.
Costly actions are valuable for they change people.
In this context, by cost I intend time, money and emotion. Some examples: purchasing some good-quality Personal
Protective Equipment is a financial cost; halting production for ten minutes to talk about Safety is both a time cost
and a money cost (missed profits from missed production), and having the consistency to have a monthly Safety
Meeting even when things are rushed is both a temporal and emotional cost.
Bad managers who did not internalize the importance of Core Values try to hide the costs of practicing them. They
think that the lower the cost, the better. However, by hiding the cost of an action they also hide its importance. They
miss an opportunity to positively influence their subordinates.
Good managers are not shy about these costs. They make them visible. Not in a transactional way – e.g., “We paid
$15 each for the new safety gloves, you guys better use them now.” – but in a way which is humble yet transparent,
e.g. “We paid $15 each for the new gloves, it’s a lot but we think this is well spent money, because Safety is just that
important.”
The more visible the costs and the higher they are, the more they will demonstrate to the workers the importance of
embracing Core Values.
Do not misread the above and think that artificially inflating costs is a good thing: it is not. If a pair of good-quality
safety gloves costs $15, saying that they cost $30 to your subordinates or buying a more-expensive-yet-just-as-good
pair will only pass the message that you are a poor purchaser. The point is not to overspend, but to be transparent
with costs.
SUMMARY
Core Values are difficult to implement because they are costly. Core Values have short-term costs and long-term
benefits. Even though the short-term costs are outweighed by the long-term benefits, employees must be confident
that they won’t be punished in the time frame between the costs and the benefit materializing by a manager who
would only consider the former.
Core Values succeed when it is conspicuously admissible to pay their costs. Visible costly actions are the only
way that a manager can pass both of the following messages: “there are long-term benefits that justify paying the
short-term costs of practicing our Core Values” and “you will not be punished for incurring a short-term cost
because you will always be able to point a finger at me and saying ‘I was doing like him’”.
Cost as a signal. Words are cheap; actions are costly. Bad managers hide the costs of their actions; good managers
show them, without transactionality.
Conspicuous actions. Words can be misinterpreted (“I didn’t really mean this”), actions cannot. Because they are
visible and material, they are conspicuous and likely to become norms.
Culture is created by visible costly actions, not by perks and terminology. Culture is made of time- and cost-
expensive rituals which are conspicuously perceived as worthy.
The 4th Principle
of Operational Excellence:
In this chapter, I will talk about reward and punishment, praise and reprimand: how to apply individual outcomes to
the performance of your subordinates. When I mention rewards and punishments, I do not limit myself to raises,
promotions, awards and disciplinary rulings. I include them, but also consider nice words, assignments to desirable
or undesirable projects, letters of merit, opportunities for personal growth, and so on. Similarly, when I mention
praises and reprimands, I do not only intend public exhibits of appreciation or disapproval, but also 1-on-1
conversations. Managers have a whole range of tools at their disposal to apply individual outcomes to the actions of
their subordinates, and they should always choose the most appropriate one, as explained further below.
Let me make clear one thing: applying individual outcomes to the performance of your subordinates against
their objectives as consistently as possible is not about squeezing every single bit of productivity out of them.
It is about treating them fairly and giving them the opportunity to work in a place where good work is useful and
rewarded, where they will never have to feel bad because their manager didn’t notice their work or where a
colleague who is slacking is treated just the same as them.
The objective of performance management is not compliance or short-term productivity. Performance
management is about avoiding motivational losses, so that long-term productivity can become a worthy goal,
for the employees too.
The difference between squeezing every single bit of productivity and treating employees fairly is in setting humane
objectives, which are ambitious yet attainable and do not require workers to go in self-destruction mode to complete
them.
This point will be further explored in the next chapter, “The Role of The Manager”.
SUMMARY
Good managers find the time to consistently reinforce change by restricting it to a single new habit and a few new
people at a time.
They find the energy to do so by acknowledging that consistency is the most important attribute of a good manager.
Great companies promote consistency of management as a Core Value and make it trickle down from the top
through costly tradeoffs performed by the Leadership, thus ensuring that no manager misunderstands its importance
Good managers are fair, not loyal. Workers say that they want loyal bosses, but what they really want is fair ones.
This because someone cannot be loyal to everyone at all times, but he can be fair to everyone every time.
Paradigm shifts
The Four Principles of Operational Excellence introduce four paradigm shifts.
The First Principle introduced a paradigm shift from “understanding objectives is the subordinate’s responsibility”
to “assigning unmistakable objectives is the manager’s responsibility.”
The Second Principle introduced a paradigm shift from “compliance brings results” to “compliance alone doesn’t
bring results; accountability to results does.”
The Third Principle introduced a paradigm shift from “management has to be efficient” to “signals must be costly to
be effective.”
The Fourth Principle introduce a paradigm shift from “taking right decisions is a matter of pragmatism” to “whether
a decision is right is determined by how it will influence the future behavior of employees.”
The Role of The Manager
Before moving on to the Eight Best Practices, it is worth spending a few pages on the role of the manager.
Good managers do their job well today, because yesterday they planted the seed for effective management: clarity.
Bad managers take decisions based on how they influence their world today. Good managers take decisions based
on how they influence the future behavior of their subordinates.
LEVERAGE
Doing the work of one of your subordinates is a low-leverage action: spending ten minutes of your time creating the
same output as ten minutes of your subordinate’s time.
Training is a high-leverage activity. If you spend 1% of your time training your 8 subordinates so that their output
improves by 1% each, your action had an 8x leverage.
The higher the leverage of the activities you spend your time on, the higher your contribution to the effectiveness of
your team.
Avoid spending your time in low-leverage activities (your subordinates’ job, reports, etc.) and spend it on high-
leverage ones: long-term decisions, training, improving clarity, preventing motivational losses.
OVERCOMMUNICATION
You only communicated something when it feels you overcommunicated it. Managers are smart people who do not
want to question the smartness of their subordinates by repeating. Therefore, the expectation that managers must
overcommunicate has to be made explicit to avoid politeness getting in the way of effectiveness.
I like management consultant Patrick Lencioni’s definition of overcommunication[12]: “employees understand how
they contribute to the success of their organization. They do not spend time speculating on what executives are
really thinking.”
Don’t feel bad repeating yourself, it is worth it.
Overcommunication has to be costly: a footnote in a slide deck won’t do. Show up in person.
COMMUNICATING MEANING
Employees work well when they work on something meaningful and they know it.
Almost any job is meaningful, for it enables others to enjoy products and services. For example, in a memorable
1960 speech to Hewlett-Packard employees, cofounder David Packard said “in those areas where we are making
instruments, we are supplying about one third of the country's total requirements […] it indicates that we have a
responsibility, in that we are making a very major contribution to the total technical effort of this country. Your
efforts are not only worthwhile but you are doing something which is really significant in terms of total technical
effort. You have seen photographs of important scientific work being done – and those photos include HP
instruments. Those of you who visit the labs of our customers find our instruments are being used in very important
work; the advancement of science, defense of our country, and many other areas. So, don't overlook our
responsibility.”
You can do the same as Mr. Packard did in his speech above: explain to your subordinates how the products of your
organization contribute to the life of their users.
Do not assume that your subordinates already know how their efforts contribute to others, and do not assume
that telling them is an insult to their intelligence. People need to be explicitly reminded of the worth of their
efforts, even if they know it already. They need to be reminded every month, so that once they have a bad day,
frustration does not find any fertile ground to grow onto.
It is the job of managers and supervisors to let their subordinates know about the meaning of their work in an
emotional way: what emotions do the products produced by your organization create in their users, directly or
indirectly?
As a manager, it is your job to help your subordinates understand the meaning of their work and to ensure
that they are, in turn, helping their own subordinates do the same.
DO NOT PROJECT
I’ve seen many managers becoming an issue for their team by projecting their own problems and insecurities on
them. Perhaps it’s you too. Or perhaps not. Either way, when you have a problem, work on it yourself or with your
own manager; do not project it on your team.
Management Walks
If a manager does not know what goes on in his own Operations, he will not be able to manage them properly. If the
subordinates of a manager do not see him spending time where Operations take place, they will not trust that he can
manage them properly. For these two reasons, it is critical that managers spend time where the work they manage
takes place.
The Toyota Production System (TPS) has a term for this, Genchi Genbutsu – “Go and See”. According to the TPS,
in order to truly understand a situation, one needs to go to “genba” – the “real place” where work is done.
However, getting a practical knowledge of operations and being seen getting a practical knowledge of operations are
only two of the three reasons why good managers spend time at the place where work is done. Taking visible actions
is the third one.
Decisions taken in the managers’ office remain in there. They do not have the power to affect how their
subordinates work unless the manager translates them into visible actions at their subordinates’ workplace.
In order to do that, good managers use Management Walks.
MANAGEMENT WALKS
Management Walks are regular instances in which a manager takes the time to physically walk where his
subordinates spend their time. This includes both their direct subordinates and, most importantly, everyone else
below them. Even the CEO, to be a good manager, should spend at least one hour a month on the factory shop floor,
observing the workers there and directly interacting with them with visible actions to show them what the priorities
of the company are.
Other Operational Excellence systems have similar practices called “Gemba Walks”, “Line Walks” or
“Observations”.
Audits
Audits are scripted Observation Walks. Instead of having the observer simply walk in an area and perform free
observations, Audits use a checklist. Later in this chapter, you will find some examples.
The person performing the Audit walks in the area being audited with the checklist in his hand and, one by one, for
each point of the checklist, it checks whether it is being observed or not. If it is observed, he marks it accordingly on
the checklist and compliments a nearby worker for it. If it is not, he marks it as incomplete and interacts with a
nearby worker as he would do during an Observation Walk.
At the end of the Audit, the checklist is sent to the supervisor of the area being audited and to the local HSE
manager (even if just part of the audit covers safety). The result is annotated somewhere visible, such as a chart on a
wall of the plant or of the office, where progress can be tracked.
Before going into the details of how an audit is performed, by whom and how often, let’s first see an example
checklist.
ACTION POINTS
1) On Word, Excel, Google Docs, or a similar software, create an Audit checklist for the office or plant
where your subordinates work at.
2) If you are a Line Manager or Supervisor, book in your calendar a monthly 30-minutes slot in which to
perform the Audit. If you are a Manager, schedule a meeting with your subordinates in which you will
ask them to perform regular Audits (make sure that you set clear expectations as per the First and Second
Principle of Operational Excellence, and make sure that you consistently evaluate their performance at
Audits as per the Fourth Principle of Operational Excellence).
3) Book a 30-minutes slot in your schedule 3 months from now in which you will evaluate your auditing
process, making any necessary adjustment to the process. If you are a manager, invite your subordinates.
Best Practice #3:
Weekly meetings
To understand the impact Weekly Meetings and their role in shaping how things are done in the company, let’s see
them from the point of view of its attendees.
- Whether the meeting starts on time and what is the treatment reserved to the attendees who are late will
inform the attendees upon whether time is considered an important resource in this organization.
- The first item on the agenda will inform the attendees on what should be kept in mind at all times during
the rest of the week.
- Whether the organization’s Core Values are mentioned during the Weekly Meeting will inform the
attendees on whether they are still relevant.
- Which tradeoffs are explicitly mentioned by the manager during the decisions (or communication of
previously taken decisions) will inform the attendees about the tradeoffs they can make during their day-
to-day work. In particular, what will be mentioned as non-compromisable by the manager (and
demonstrated through his choices) will be considered as non-compromisable by the attendees too.
- Conversely, if some Core Value or standard has been compromised during the Weekly Meeting (for
example, a decision showing that the Core Value or standard is not absolute), the attendees will deduce
that it can be compromised by them too. Not taking the time to talk about a Core Value during the
meeting counts as having compromised it.
AT THE BEGINNING
The manager thanks the attendees for having arrived in time, explaining it is a sign of respect for each other’s time
and work. This action achieves multiple results: it makes people feel it was worth to arrive on time, it makes people
want to arrive on time not to feel like an outsider who doesn’t respect the other members of the teams, and it
clarifies that people are required to be on time not because the manager is rigid, but because he is respectful of his
subordinates’ time.
THE AGENDA
The first topic on the agenda should be an update related to one or more of the organization’s Core Values. For
example, the manager could open the Weekly Meeting asking if anyone in the team has observed any unsafe
behavior or condition (if safety is a Core Value), or if there has been any exceptionally satisfied customer (if
customer satisfaction is a Core Value). I call this a “Core Value Review”.
Most of the meeting should be about communication, mostly from the manager to the team. The manager
communicates whatever piece of information he might need to communicate to his team and uses any opportunity he
can find to reinforce Core Values and standards.
If there is any decision to be made, these should happen after all communication has taken place.
HANDLING DISCUSSIONS
It is possible that during the meeting, participants enter into heated discussions. This is okay as long as they are
about issues and not about personalities. If any comment is made upon someone’s personality, the manager
should immediately refocus it on someone’s behavior. For example, if an employee says that “John is lazy”
because it takes multiple emails to get him to handle some request, the manager should reply along the lines of “You
mean that John is slow to respond to internal requests?”. This achieves multiple results: it makes John more likely to
comment constructively rather than defensively and it makes the feedback more precise, allowing to pinpoint what
could be improved.
If the manager is consistent in reminding his subordinates that “here, we only discuss issues, not personalities” every
time that someone critiques a colleague as a whole (rather than critiquing one of his behaviors), then in a few weeks
his subordinates should have learned to formulate their comments appropriately. It is extremely important that the
manager does not let a personal comment pass even once without reminding the team that they are not allowed. If he
does, all his good work will be destroyed and in no time the team will be back to commenting on each other with
nonconstructive feedback.
HANDLING DECISIONS
If, at any point during the meeting, two participants have a disagreement, the manager should let them work it out;
possibly, outside of the meeting, in order not to waste everyone’s time.
If multiple participants have a prolonged disagreement on a decision which is of interest for the whole team, then the
manager is supposed to step in and take the decision himself, as the final arbiter.
Some managers might be hesitant to do it, not to displease anyone. They should remember that usually people do not
get angry if someone took a decision they do not like, but they get angry if someone took a decision without hearing
them out. As long as the manager collects the input of everyone who has an opinion and makes sure these people
trust that they have been heard, then he can confidently take a decision and know that his subordinates will not be
angry with him. They might have other emotions – such as frustration – but they won’t be personally angry with
him.
While listening to the opinions of their team members, managers should be careful not to use their own assumptions
to interpret the words they hear. In order to truly listen, one should listen not only to the interlocutor’s words, but
most importantly to the interlocutor’s assumptions.
ACTION POINTS
1) If you do not have regular Weekly Meetings with your subordinates, schedule one immediately.
2) Book a 15-minutes slot in your calendar immediately after each of the first three meetings, in which you
will re-read this chapter and think on what went well and what can be improved.
Best Practice #4:
One-on-one Meetings
“People who think one-on-one meetings are a bad idea have been victim of poorly-
designed ones.” – Silicon Valley entrepreneur Ben Horowitz
One-on-one Meetings are a powerful tool to gather intelligence, reinforce priorities, assign accountability and review
performance, all in an intimate setting.
They are such a powerful tool that every manager should have at least one a week with every single one of his
subordinates. For some industries such as software development, where subordinates benefit from long
uninterrupted stretches of work, One-on-one Meetings can happen once every two weeks. Most industries instead
benefit from weekly ones.
One-on-one Meetings should last at least half an hour, even if there is nothing to discuss, especially if there is
nothing to discuss. This because there is never nothing to discuss. If it looks like there is nothing to discuss, it
means that the manager should get better at asking questions, or better at handling silence.
The most useful pieces of information come out after a long, awkward silence: often, that’s the moment when the
subordinate will voice what he would not voice before – that’s usually the most important piece of information.
Bright Spot Analysis[15] is a powerful tool to find ideas to improve your Operations that work.
Bright Spot Analysis is a simple Best Practice consisting of 3 steps: looking at who’s the best performer in your
area, understanding what he does differently, and figuring out whether it’s something which could be replicated by
the rest of the employees.
NO CHERRY-PICKING
Cherry-picking is the process of making one’s opinion of a person or of a group of people based on one single aspect
of their performance, rather than on their overall one.
For example, a rule for personal life is never to envy anyone you wouldn’t fully swap your life with. Envying
someone for a single aspect of their life is pointless, for he probably made trade-offs which would not be good for
you.
Similarly, when performing Bright Spot Analysis, managers should be careful not to cherry-pick performance data
points and instead focus on overall performance only. If a team or individual is the best one at a single aspect of
their job (for example, production output) but has subpar overall performance (for example, they lack in quality of
output), do you really want to replicate the procedures they use to produce at higher speeds?
SIDE EFFECTS
Every intervention and every new practice or procedure comes with side-effects: the time, energy and money needed
for its implementation and the eventual loss of morale and motivation incurring in everyone who gets told that “the
way he was working before was wrong”.
It is important that managers using Bright Spot Analysis (or Dark Spot Analysis) consider, before the third step,
whether any new practice or procedure they would implement would bring enough benefits to compensate all its
side effects – leaving some margin of safety for the possible presence of hidden ones.
ACTION POINTS
1) Schedule in your calendar a 30-minutes slot in which you will perform the Bright Spot Analysis. (This is
a low-priority task; the Action Points of the previous Best Practices have a higher priority.)
2) When the time for the Bright Spot Analysis comes, re-read this chapter and then try to apply its contents.
3) Schedule in your calendar a follow-up 30-minutes session in which you will perform another Bright Spot
Analysis.
Best Practice #6:
“When companies choose chat first, they revert into an almost oral tradition.” – David
H. Hansson (DHH)
In all kind of organizations, writing down procedures, rules, standards and Core Values is important for
three reasons. First, it makes them permanently available. Anyone can check them at any time and know how
he is supposed to act. Second, it makes them conspicuous. If you act according to written tradition, you don’t
have to think about justifying your actions to others (or risking being wrong). Third, it allows for fair
application of individual outcomes.
A company that only relies on oral tradition will find itself with many problems. Between others, employees not
knowing what to do, receiving contrasting input about which tradeoff to make, and employees being able to justify
selfish behavior saying, “what he said wasn’t clear” or “but I was told otherwise.”
In companies, a big part of written tradition is constituted by Standard Operating Procedures (SOPs).
SOPs are sheets detailing the most critical procedures employees might encounter in their work, regularly reviewed
and stored somewhere easy to be accessed by anyone who might need them.
Standard Operating Procedures fulfill three purposes. First, they ensure that any worker who might need to perform
a business-critical task has a reference to use. Second, they ensure that if anything goes wrong, there is an objective
reference to use to verify whether anyone did anything wrong. Third, they ensure that when a change is applied to
the current operations (for example, a new piece of hardware is added or a procedure is changed), it is possible to
check all other procedures for possible collateral effects.
MANAGEMENT OF CHANGE
In companies which are far from achieving Operational Excellence, procedures only contain a title, a list of steps
and perhaps a signature. They neglect Management of Change (MoC): the checks which are needed to ensure that
whenever something changes in the environment in which the procedure takes place, the procedure is adapted as
well; and to ensure that whenever the procedure is about to be changed, it has been checked whether any change in
its environment is needed.
Therefore, all SOPs should contain the additional components listed above. Otherwise, they will work until they
inevitably don’t.
CONTRACTORS
Written SOPs are especially useful to manage contractors. Make sure you include them in the list of procedures to
write, and involve them while writing them.
JOB DESCRIPTIONS
Job descriptions are a particular case of SOP. In a broad sense, the requirements for a position and its task describe
part of the procedures that Human Resources and managers will have to follow to hire or promote someone to that
position.
For example, if a position requires some specific piece of knowledge, a job description that clarifies this need will be
useful to ensure that any candidate for that position is screened for that knowledge and that any person promoted to
that position is trained on that knowledge.
Job descriptions are the task of the manager who manages the role being described. In large organizations, HR
should support with the task, but the manager’s input is required.
Every single position in the company should have a job description. This should be a written document fulfilling all
requirements for Standard Operating Procedure (such as an expiration date, a signature, a purpose, etc.).
In particular, job descriptions should contain both the know-how requirements for the position and the list of tasks
the position is responsible for.
Some of the best managers I know prepare documents with a list of behaviors expected from the position (and of
behaviors which are expected not to take place), and circulate that document internally, privately (with those in that
position) or publicly (by hanging that document somewhere visible in the office or in the plant).
META-PROCEDURES
There should also be procedures regarding procedures: a procedure to create SOPs, one to update them, and one to
review them, at least.
ACTION POINTS
If you have the authority to write procedures, do the following.
1) Write the three meta-procedures described just above, according to the content of this chapter. Make sure
that in the procedure for creating SOPs, you clarify which areas of competence should contain
procedures and who is responsible for writing each.
2) Schedule a 30-minutes meeting with each of the people responsible for writing procedures and go
through the contents of this chapter with them, assigning them the objective of writing the procedures for
which they are responsible within a reasonable time frame. Most probably, your company already has
some written SOPs. In this case, make sure that both the following are done: old SOPs are checked and
rewritten if necessary, and the need for additional new SOPs is evaluated.
3) Schedule some follow-up meeting to check the progress against writing procedures.
4) Once the procedures are written, make sure that the appropriate people review them (HSE, Line
Supervisors, etc. – anyone directly involved in using them or in managing people using them should be
informed and be given the chance to review them, with the addition of relevant technical specialists, if
any).
5) Delegate the task of printing and distributing the SOPs.
6) Make sure that each Manager and Supervisor is assigned the task of going through each procedure with
each of his subordinates who would be affected by them.
The topic of SOPs is highly complex and the action list above is likely non-exhaustive. Please use your best
judgement, follow the Four Principles of Operational Excellence and contact an industry expert if appropriate.
This is likely the most difficult and lengthy Best Practice to implement – and yet, a very important one.
Best Practice #7:
Surfacing Problems
JUST IN TIME
In business school, many would describe Just In Time as the concept of having components arriving directly at the
production line the moment they are needed, in order to reduce the financial costs and handling time associated with
having them delivered to a warehouse first.
This is only partially correct.
While it is true that having components handled twice (once to go from the delivery truck to the warehouse, and
once from the warehouse to the production line) and renting space just to have components sit there are two
unnecessary costs which do not provide any value to the customer, that is not the most important advantage of Just
In Time.
Warehouses are buffers, and buffers protect against supply volatility. For example, if you have a warehouse with
enough components, you will be able to continue production even if the truck delivering components to your
production line is late.
A company with a buffer (such as a warehouse with enough components to last a week) will not consider a truck
being one day late as a problem. This means that no one in the company will take any steps to ensure that the truck
comes on time. If one day, eventually, the truck is one week late, then production will have to stop and the company
will be unprepared on how to react.
Conversely, a company without a buffer (no large warehouse for components) will consider even a one-hour delay
of the delivery truck as a problem and will take immediate action to ensure that the truck comes on time, every time.
As a consequence, its operations will become much more robust and efficient.
Buffers prevent problems from surfacing, until it’s too late. Just In Time (and other techniques which reduce
buffers) allow problems to surface so that they can be solved before it’s too late.
Just In Time is about removing buffers to surface problems.
PROBLEM SOLVING
The two examples above, Just in Time and the Red Rope, are good introductions for the topic of this chapter: how to
implement problem solving techniques and how to implement incentives to make sure that those techniques are used
proactively (before serious problems take place) rather than reactively.
Escalating problems to upper management or to experts is an extremely slow approach, for two reasons. First, it
takes time for an escalated issue to reach the person who will solve it, and for her to act. And second, it takes time to
even begin the escalation, as line workers are wary of being seen “creating problems” and would often wait a few
hours, days or weeks before getting themselves to escalating the issue.
Of course, this is not good. Problems grow the size they need in order to be acknowledged. An organization
that is slow in acknowledging problems will find itself with big problems.
The alternative is to set in place systems to tackle problems immediately as their first symptoms appear, or even
before that.
There are two complementary approaches for doing so: decentralized problem solving and measuring leading
indicators.
TOOLS
There is an abundance of problem-solving tools and techniques to be used by line workers and line management to
solve operational problems.
The most famous one is perhaps Six Sigma. Whereas Six Sigma cannot be used for all problems – most of its tools
only apply to contexts whose characteristic distributions are Gaussian[16] – it is useful to provide line workers and
line management with tools to solve problems by themselves and in a structured way.
Another well-known tool is the “5 Whys”, in which the worker interrogates himself on the cause of a defect for a
few times, typically five, with each answer becoming the basis for the next question. (For example: “Why did my
teammate injure himself?” “Because he tripped on a cable.” “Why was the cable on the floor?” “Because it
connected a tool to the plug on the other side of the room.” “Why wasn’t the tool plugged to the closest side of the
room?” “Because there was no plug there.” The solution: to ask an electrician to install a plug on that wall). In my
experience, the right number of iterations to stop at is not 5, nor any other precise number. It is when taking care of
that problem would ensure that no similar incident will ever happen again.
In general, problems are solved only when the action addressing them answers positively the question “will doing
this prevent the same problem from occurring ever again?”
Bright Spot Analysis and Dark Spot Analysis (Best Practice #5) are great tools to solve problems proactively.
EXPECTATIONS
Whereas many organizations understand the need for decentralized problem solving and deploy tools for line
workers to solve problems, only a few set the expectations that line workers are to actually use them.
To some managers this might seem puzzling – if we gave them the tools, of course they are expected to use them –,
but the reality is that unless the expectations are explicit and linked to personal outcomes, tools will not be
used.
Moreover, if any manager explicitly communicates the expectations that line workers are supposed to solve their
problems by themselves, but at any point he punishes one of the workers for having done so, the message that will
pass to the team is: you are not really supposed to solve problems by yourselves (“punish” is used here in the
broadest way possible – even just a bad look or rolling eyes “punish” the worker having tried to solve a problem).
Of course, there might be circumstances in which line workers are expected to escalate problems. Procedures or
rules-of-thumb must be put in place to clarify whether an issue is expected to be escalated or to be solved locally.
It is critical that managers both deploy problem-solving tools and constantly reinforce the expectations that workers
are supposed to use them autonomously. The efficacity of decentralized problem solving in your organization will
be the lowest of the two.
LEADING INDICATORS
Leading indicators are a great tool to recognize problems before they take place. Let’s see a practical example,
related to workplace safety.
In 1931, US safety manager Herbert Heinrich noticed a relationship between incidents in factories. For each accident
causing a serious injury, there would be about 29 accidents causing a minor injury and 300 accidents causing no
injury. These exact coefficients got later disproved, but Heinrich was onto something: for each death there are
indeed many serious injuries, for each serious injury there are many minor injuries, for each minor injury there are
several accidents causing no injury (also known as “near misses”, for example, a brick falling from the roof but
hitting no one), and for each accident causing no injury, there are many unsafe behaviors (such as a worker walking
in the plant with no safety helmet) and unsafe conditions (such as a sharp edge near a walkway). These relationships
can be displayed as a pyramid, as in the image below.
Now, let’s make a thought experiment. Imagine that, in a fictional company, there has been one workplace death
four years ago, one three years ago, one two years ago, and zero deaths last year. Can we say that the company
became safer?
4 years 3 years 2 years Last
Time
ago ago ago year
Workplace
1 1 1 0
deaths
No, we cannot. Perhaps the plant’s current safety level warrants 0.75 deaths per year, and last year the employees of
the company just got lucky. Maybe, next year there will be another death (or two). The sample is too small, and the
results too volatile.
Trends measured at the top of the pyramid are too volatile to have any predictive value.
Now, let’s imagine that in the same company, 25 employees recorded an injury four years ago, 30 three years ago,
15 two years ago and 5 last year.
4 years 3 years 2 years Last
Time
ago ago ago year
Workplace
25 30 15 5
deaths
Can we say that the company got safer?
Perhaps; we cannot be certain. Though the sample is now large enough to enable us to spot more reliable trends,
other possibilities might invalidate the results. It is possible that, starting two years ago, the management covertly
warned the employees and asked them not to report injuries. Also, there is the possibility that operations that
produce light injuries did get safer, but that the operations that cause no light injuries but might kill employees (such
as electrical maintenance operations) did not get safer. Finally, trends measured in the top half of the pyramid lack
data on improvements relative to rare threats. For example, employees may have now a lowered probability of injury
from common sources of accidents but are perhaps still a high risk of injury from infrequent ones, such as a fire.
Now, let’s imagine that in the same company, random observations showed that four years ago 50% of the
employees were wearing a safety helmet in the areas where their use is required; three years ago, 80% of the
employees; two years ago, 90% of the employees and last year, almost 100% of the employees.
Can we say that the company got safer? Yes, most probably. There is a correlation between the consistency of safe
behaviors and how safe it is to work at a plant. Given that most incidents take place because of unsafe behaviors, the
workers are safer now.
Trends measured at the basis of the pyramid of risk are more reliable, both because of a larger sample and
because of a lower number of assumptions needed.
Moreover, indicators at the top of the pyramid have a disgraceful property: they measure events that already
happened. For this reason, they are called lagging indicators. Companies and individuals which measure lagging
indicators tend to be reactive: they only act when the lagging indicator shows a problem: after the negative event
took place, when it’s too late. Conversely, the indicators at the bottom of the pyramid can tell us whether negative
events will occur, before they happen. They are leading indicators. Companies and individuals which measure
leading indicators tend to be proactive and usually act to avoid the negative event before it happens.
If a company only increases the frequency of safety trainings after a workplace death occurs, it is bound to have at
least one workplace death. If, instead, a company increases the frequency of safety trainings the moment it notices
that not all employees are following the safety guidelines, then it will probably be able to prevent the deaths.
Measuring trends at the bottom of the pyramid allows to be proactive and to prevent negative events;
measuring trends at the top causes to be reactive and to suffer from negative events.
USING LEADING INDICATORS
In order to use leading indicators, managers have to tie at least partially performance rewards to leading indicators,
rather than to lagging ones.
(I remind the reader that there are various types of performance rewards, including financial rewards, rewards of
recognition and noticing the good, as well as disciplinary punishments or punishments in the form of admonishment.
It doesn’t only have to be promotions and bonuses, or their absence.)
When harmful negative events are less frequent than positive ones, there is a risk of overoptimization: maladaptation
to a temporary lack of harm. For example, a few lucky months with no injury might make the workers complacent
and take unnecessary risks. Hence the importance to reward leading indicators (such as the number of people
wearing the safety helmet) in addition to lagging indicators (such as the number of injuries) to prevent people from
optimizing for other metrics (for example, not wearing the helmets in order to save a few seconds).
By tying consequences (rewards and punishments) to leading indicators in addition to lagging ones, the
frequency of negative events increases, causing the incentive to optimize for the frequent small profits to
disappear. Let’s explore this phenomenon using an example.
A sales manager whose compensation is tied to his sales (a lagging indicator) will focus all his energy and time on
making the numbers for the current quarter. If he has an additional hour, he will spend it on making one more phone
call or on sending one more proposal. He will favor small unprofitable clients who have a faster purchasing process
over bigger ones to which a sale might take quarters. He will try to squeeze every dime out of every deal, getting
some short-term profits but damaging the long-term relationship with the client. He might even be tempted to sell
defective products, or products he knows would offer no benefit to that particular customer.
Conversely, a sales manager whose compensation is tied to leading indicators (such as client satisfaction, which is a
predictor of repeated sales[17], sales trainings attended, which are supposed to improve future sales, and customer
research and qualification, which are supposed to improve the quality and profitability of customers) is more likely
to bring great long-term results.
When I present the concept of the pyramid of risk and of leading indicators, people tend to understand it rather
easily. However, while putting it into practice, very often they make a key mistake. They do pay attention to leading
indicators and they do measure them, but they fail to tie them to individual outcomes. If a bad performance on a
lagging indicator does not impact the employee in any way, then he will not change his behavior.
As illustrated in the chart below, only the top half of the pyramid is inherently linked to physical harm;
consequences such as emotional or career rewards must be actively tied to the indicators at the basis of the pyramid
to ensure that employees change their behavior to improve them.
SOLVING PROBLEMS WITHOUT USING SHORTCUTS
Problems disappear only when their root cause is addressed. Otherwise, if the problem is solved but not its root
cause, the latter will act as a source of new problems.
Shortcuts are the shortest way to another instance of the same problem.
Good managers insist that root causes are solved; not superficial problems.[18]
Therefore, they do not reward those who solved the former without taking care of the latter.
INCIDENT INVESTIGATIONS
A particularly effective problem-solving tool is incident investigations: a procedure that is triggered by safety
incidents, quality incidents and ethics incidents and whose aim is to find their root causes.
Incident investigations are a necessary but not sufficient tool: they are great to address problems which already
manifested but cannot take care of problems which still have to manifest. Therefore, they are to be implemented
together with the other tools described in this chapter.
Incident investigations are performed by a committee created ad-hoc immediately after the incident.
Incident investigations are as effective as the level of the highest person involved. Therefore, it is advised that
the CEO or the highest manager resident at a geographical location (e.g., the Plant Manager) are part of the
committee, if the incident is consequential enough (a severe injury, a quality concern which led to a recall, a rogue
employee which did or could have caused harm to the company, etc.). Their time is limited so they are not expected
to actively conduct the investigation; however, they should at least order the investigation and be informed of its
results. Because their time is limited, their participation to the investigation is a costly (thus effective) signal of its
importance. If a high manager is part of the investigating committee, the committee will find it easier to collect the
information it might need or to implement any corrective action aimed at avoiding the occurrence of similar
incidents in the future.
The purpose of the incident investigation committee is to ascertain what happened, investigate the root causes of the
incident, and propose recommendations so that no incident with the same root cause will ever take place again.
The committee should conclude its investigation with a written report answering the three following questions: what
happened, what was the root cause, what should we do about it. In case of a quality incident, the report should be
sent to the area manager, to the QA manager, and, if appropriate, to the global QA manager and/or to other area
managers whose operations are similar enough to be likely to benefit from the learnings of the investigation. In case
of a safety incident, the report should be sent to the area manager, the local HSE manager, the global HSE manager,
the Operations Manager and the Plant Manager. These five roles are responsible for both taking immediate action
based on the recommendations and to evaluate whether other geographical locations of the company could benefit
from implementing the same measures (and, in this case, contacting them; members of the Top Management should
be contacted as appropriate).
The paragraph above is provided as a simple guideline; each company should choose the list of people to be
informed as it works best. However, such list should be written in a procedure itself, so that everyone knows who
the results of the investigation should be sent to.
It might happen that the investigation committee lacks the technical resources to interpret what happened during the
incident, to find its root causes or to propose corrective measures. In such case, they should involve a technical
expert (internal or external to the company) as appropriate.
Incident investigations are not about blaming the person responsible for the incident (though he must be hold
accountable in case of negligence). They are about finding the root cause of the incident and preventing its
reoccurrence in the future.
SUMMARY
Companies with Excellent Operations implement a variety of problem-solving tools, most of them decentralized,
and constantly reinforce expectations about who is supposed to use them.
Such companies act on both incidents and declining leading indicators; they have systems in place to tackle the root
causes of the problems that materialized in the past and of those which didn’t happen yet.
ACTION POINTS
1) Schedule a meeting with either your HSE manager or your QA manager and implement an incident
investigation procedure. Make sure that a Standard Operating Procedure is also written.
2) Think about some leading indicators which are relevant to the areas you manage. Assign to someone in
your team (it might be yourself) the task to measure and improve them.
3) The next time decisions are made or problems are addressed, make sure that it is done at the lowest
competent level.
Best Practice #8:
Visual Aids
Best practices are tools to practically apply the 4 Principles of Operational Excellence. Whereas the seven previous
Best Practices required at some point the physical presence of the manager, the eight one does not.
Visual aids comprise posters hanged on walls, labels describing hardware, barriers limiting action and any other
form of visual communication meant to remind or guide the actions of whoever sees it.
Visual aids serve two purposes. First, to provide visible tangible reminders of what is important, even when the
manager is not there. And second, to provide an uncontestable objective reference for the standards and objectives:
if it’s been hanging on the wall for a month, no one can say it hadn’t been possible for them to know.
If I had to choose a sentence to summarize the first three Principles of Operational Excellence, it would be: “make
sure that the important cannot be misunderstood”. Visual aids are a key Best Practice to ensure this, together with
Observation Walks and Audits (which provides on-hands feedback), Weekly and One-on-one Meetings (which are
occasions to re-state the important), and Standard Operating Procedures (which are another form of objective
reference, though it has to be “pulled” and can hardly be “pushed” in front of the people who need to see it, when
they need to see it).
The most common four forms of visual aids are: posters, poster charts, labels and barriers.
POSTERS
Posters are large prints hanged on the walls of offices, walkways, factories and warehouses. They usually depict or
describe rules, standards, priorities and Core Values. For example, a poster hanged on the wall of the warehouse
might remind the workers of the safety rules they must observe while in there, or a poster hanged on the walls of an
office might remind its workers that “Environmental Sustainability” is a Core Value of the company.
Some managers dismiss the importance of posters saying that their subordinates already know what’s written
on them. These managers forget that Communication doesn’t happen when a message is first said; it happens
when it cannot be mistaken anymore.
A message has never been communicated enough unless the manager feels it had been way overcommunicated. No
message is clear enough to justify not putting it on posters.
Moreover, posters are a conspicuous reference; therefore, they provide a function that the spoken word alone cannot
provide. Any worker can tell the manager “You didn’t say that!”, but no worker can do so if the message has also
been hanged on the wall.
As a rule of thumb, if no Core Value and Standard is hanged at least once in every office floor, factory floor, canteen
and warehouse, then your company needs more posters. (Multiple Core Values or standards can share the same
poster, though.)
POSTER CHARTS
Poster charts are posters which show a chart tracking the evolution of one or more key metrics over time.
Poster charts differ from normal charts in two ways: they are hanged somewhere visible to all workers in a given
area, and they are clear enough that the message they convey can be read by someone passing by without him
having to stop and wear his glasses. Hence: not too much text on them.
Their function is not (only) to inform the workers of the trend of some key metric. Rather, their main function is to
remind the workers of some key output of their job which they should keep at the top of their mind at all times.
The best poster charts contain a title large enough that it can be spotted from 2-3 meters away. This way, workers
passing by the room will be reminded of what matters without having to stop by the chart. Also, workers will be
more confident that other workers saw it too.
As a rule of thumb, every factory or office worker should either be working in front of a poster chart or passing in
front of one while walking from his workstation to the toilets.
LABELS
Labels are small pieces of paper, fabric, plastic or similar material next or attached to a critical piece of hardware.
For example, a label might be a sticker next to a button which explains what happens if pressed, or it could be a
piece of plastic connected to a key that explains what the key is for.
Labels could also be writings next to critical pieces of hardware. For example, a bottle might be labeled with its
contents or with the risks associated with its contents (e.g., “inflammable”).
Finally, labels could also be panels indicating a direction. For example, an arrow indicating where the emergency
exit is.
Great companies use labels extensively. Every critical button, tool, container, shelf, pathway, lever, valve and
indicator is clearly labeled.
Great companies do not assume that, because their workers have undergone training, they do not need labels. Labels
(and visual aids in general) are not there to protect against inexperience. They are there to protect against
fatigue, rushing, and other mental conditions which might cause an otherwise competent operator to commit
a mistake.
Some labels, in addition to preventing mistakes, also make operations faster or more efficient. For example, some
factory workers attach stickers of different colors (blue, yellow, pink and so on) to their tools and then attach
stickers of the same colors to the table they work on. This way, they know where each tool is supposed to rest on
their table. Having each tool at the same place translates into faster working speed, if a high number of tools is
involved.
A particular form of label are signs on the floor which indicate walkways or separate areas. For example, most
factories have the areas where workers are supposed to walk delimitated with long clear stickers. These labels serve
three functions. First, they keep workers outside areas where they’re not supposed to be (such as forklift
passageways). Second, they guide the movements of workers, making it easier for them to get safely where they
want to go. Third, they delimit the areas where parts and equipment can be stored, ensuring that they are
accumulated there rather than on the walkways where they can slow movement or cause injuries.
BARRIERS
Barriers are pieces of hardware which limit movement, preventing workers from accidentally walking or moving
parts of their bodies where they’re not supposed to. For example, a grid might prevent workers from entering by
mistake within the range of motion of a robot which might cause injuries.
As a rule of thumb, if you have an area which is routinely accessed by unqualified workers or which contains
moving hardware which might cause injuries (such as robots), then the access to the dangerous zones must be
limited by some form of barrier.
WHOSE RESPONSIBILITY IT IS TO USE VISUAL AIDS?
In companies with low Operational Excellence, visual aids are usually installed under the orders of the HSE
manager and are usually limited to HSE matters.
In companies with medium Operational Excellence, visual aids are additionally installed by the area manager, to
drive attention towards the organizational priorities.
In companies with great Operational Excellence, visual aids are additionally installed by each worker, in his or her
own area of competence. Workers use these aids both for themselves and for others, both to prevent injuries, to drive
attention towards what’s important and to improve the efficiency and efficacy of their own work.
If you are reading this, feel free to request to your area manager or HSE manager any visual aid you think the
workers in your area of competence might need, as appropriate. Do not wait for them to be set in place; if they
haven’t been set so far, chances are that they won’t be set in the near future either, unless you take the situation in
your own hands.
SUMMARY
Great companies make extensive use of visual aids to remind their workers about the important things.
They do not only use visual aids for things that are hard to remember; they use them for things which are
important to remember, regardless of whether they’re obvious or not.
Great companies make use of all types of visual aids: posters, poster charts, labels and barriers.
ACTION POINTS
1) Is there any tool, bottle, box or shelf space which is unlabeled? Label them (or ask the area manager or
area owner to do so, as appropriate).
2) If your subordinates’ workplace does not contain enough posters on Core Values (“enough” as defined
above), add some.
3) Which poster charts would benefit your subordinates? Create them.
4) Is any area under your management in need for barriers?
Paradigm shifts
The First Best Practice (Management Walks) introduced a paradigm shift from “a manager’s most important work
takes place in his office” to “a manager’s most important work takes place on his subordinates’ workplace.”
The Second Best Practice (Audits) introduced a paradigm shift from “inspections are to correct behaviors and
conditions” to “inspections are to reinforce Core Values and standards.”
The Third Best Practice (Weekly Meetings) introduced a paradigm shift from “weekly meetings are to communicate
new information” to “weekly meetings are to communicate old information (Core Values and standards).”
The Fourth Best Practice (One-on-one Meetings) introduced a paradigm shift from “information during one-on-ones
flows from the manager to the employee” to “information during one-on-ones flows from the employee to the
manager.”
The Fifth Best Practice (Bright Spot Analysis) introduced a paradigm shift from “innovation is about applying new
ideas” to “innovation is about applying old practices.”
The Sixth Best Practice (Standard Operating Procedures) introduced a paradigm shift from “SOPs are about
compliance” to “SOPs are about managing change (hires, promotions, purchases, innovation, etc.).”
The Seventh Best Practice (Surfacing Problems) introduced a paradigm shift from “problem solving is about taking
care of already-occurred problems” to “problem solving is about preventing future problems.”
The Eight Best Practice (Visual Aids) introduced a paradigm shift from “visual aids are about compliance in perfect
circumstances” to “Visual Aids are about avoiding mistakes in imperfect circumstances (e.g. when employees are
rushed, tired, etc.).”
What to do now
In the third part of this book, you will find a Roadmap to change the Operational Culture of your organization.
However, you might want to start small first, limiting the scope of change to your direct reports. The following
points will help you prioritize what to do over the next few days.
TODAY:
Schedule a one-on-one meeting with each of your subordinates to be held over the next few days.
Book a 0ne-hour slot in their calendar. During the meeting, clarify their individual objectives. Do not
forget to add individual objectives on Core Values. Take a blank sheet of paper to the meeting and
write down any agreed objective. The act of writing will force clarity. Also write down how you will
evaluate their progress against their objectives. At the end of each individual meeting, schedule with
the attendee the next meeting, in one-week time.
Schedule in your calendar a 30-minutes slot for your Management Walks, as described at the
end of the relative chapter.
One month from now, schedule in your calendar a 60-minutes slot in which you will take the
actions under the paragraph title “one month from now”, which you will find below.
ONWARDS:
Keep implementing the Eight Best Practices of Operational Culture and eventually ask your
subordinates to do the same, if appropriate.
Never compromise on Core Values. Never. No matter what. It is not worth it.
Behave as per your words, and if impossible, own your mistakes and take immediate action to
ensure that you will never have to disrespect your words again for the same reason.
Set weekly or monthly 15-minutes slots in your agenda for “Operational Culture Reviews”, in
which you will meditate on whether during the past week you lived the Operational Culture you
desire to build in your team, and on what has to be done differently next week.
Schedule half-yearly 2-hours slots in your calendar in which you will review this book.
Notes – The list above is non-comprehensive. It has been written with the sole purpose of giving you some quick
tips on what to begin working on as you internalize the concepts read so far. The third part of this book will provide
you with more information on rolling-out change in your organization.
Part III:
The Roadmap to Change
In the first part of this book, you learnt the Four Principles of Operational Excellence:
1) Good managers set unambiguous, individual and rewardable objectives.
2) Good managers always explicitly assign full accountability together with objectives.
3) Good managers demonstrate priorities with visible costly actions.
4) Good managers are obsessively consistent in holding their subordinates accountable.
In the second part of this book, you learnt the Eight Best Practices that transform the Four Principles into visible
action:
1) Management Walks
2) Audits
3) Weekly Meetings
4) One-on-one Meetings
5) Bright Spot Analysis
6) Standard Operating Procedures
7) Surfacing Problems
8) Visual Aids
The third part of this book is about implementing the content you’ve seen so far.
It will guide you to plan an initiative to change the operational culture of your team, plant or company, to get Top
Management buy-in, to roll-out the initiative and to sustain it over time.
Getting Buy-In
If you are a member of Top Management, you are probably already familiar with the contents of this chapter and can
skip to the next one. The following paragraphs have been written for people less experienced with getting the buy-in
to roll-out initiatives aimed at changing the operational culture of the team, plant or company they work in.
PRESENTING EVIDENCE
When you request support from Top Management, you should not only have past evidence of the effectiveness of
the initiative you are proposing, but you should also be able to present it in a way that is relevant to them.
Do not focus too much on the technical details of the initiative: they will be useful and important for you, but not for
them. Instead, focus on ensuring that your letter / presentation / request for support covers the two following points.
Past evidence that it will work. As mentioned in the previous section, make sure that you have past evidence that
your project will work, and make sure to mention it in your request.
Bottom-line impact. Every project – every single one – will be checked against its impact on the bottom line: is it
an allocation of people and money that will bring more profits than competing alternatives?
You need to answer this question – even if it is not asked, because the people evaluating your proposal will make the
computation anyway, so you might as well be the one making it for them.
To calculate the bottom-line impact of your initiative, consider both the benefits of it being implemented and the
costs of it not being implemented. For example, how much will it cost your company to keep producing components
with the current defect rate?
When you calculate the costs of continuing operating with the current problems, do not forget to also include hidden
costs. They are often much larger than visible ones. Let’s say, for example, that due to the current lack of
Operational Excellence, your company has a high injury rate. The visible costs are the costs of non-production (if
the line has to stop due to incidents) and the costs of managing the recovery of the employee. The hidden costs are
the cost of finding a replacement for the injured employee (or of maintaining extra staff for redundancy purposes),
the cost of lower quality (as the temporary replacement for the injured employee will likely be less experienced or
proficient), the higher cost of health and safety insurance (companies with lot of injuries are more expensive to
insure), the morale and turnover cost of injuries (employees in companies with a lot of injuries are more likely to
quit, increasing hiring and training costs), and so on.
GET COMMITMENT
I know of consulting companies that do not work unless the CEO (or, if engaged by a subsidiary, the Managing
Director or Plant Manager) commits to be both a participant to the initiative and a promoter of it. I personally do the
same for my consulting practice, except very particular cases.
This is so important. Unless the CEO is the first person to participate to the trainings and to set the expectations for
all the other employees, your project will not be considered a priority. As soon as the CEO talks about another
matter, that matter will become the new priority and your project will fall into oblivion (because the CEO talked
about that matter but not about your project, and this places your project on a lower level).
Do not begin your initiative until you got written commitment of personal support from the CEO (or, if your
initiative is limited to a single location within your company, from the highest role resident there). This might be a
hassle, and it might delay the start of the initiative, but it will make everything easier.
INSIST
Your role – as a professional – is not (only) to propose the initiatives you believe will be good for your company. It
is to fight for their implementation.
If Top Management refuses your proposal, do not take it as the death of your initiative. Instead, take it as a sign that
you didn’t prepare your proposal well enough. Perhaps, you didn’t understand Top Management’s point of view
well enough. Or maybe, you were not able to present your case in a way that resonated with them. Either way, it is
your responsibility to try again.
Acquire the skills you might need (presenting? Writing? Finance?), make the connections you might need, ask for
the help you might need, and then submit your proposal again.
Rolling out
FRACTAL HIERARCHY
The only way to ensure that change is quickly implemented across a large company is by leveraging a fractal
hierarchy.
Due to the necessity of achieving critical mass, a manager can only promote change over a small team – perhaps 4 to
10 people, depending to how close the manager is to them and how busy he is with other tasks. Having a manager
trying to implement change over more people is bound to fail. Therefore, only companies with a very vertical
structure (few subordinates per manager/supervisor) can afford to implement a company-wide change initiative in a
quick amount of time – and even then, the scope of the change should be limited to 1-2 new behaviors per month.
During a company-wide or plant-wide change initiative, every single manager and supervisor must be involved. It is
impossible that a single HSE manager, for example, rolls out a company-wide change initiative over a small amount
of time. He could do so over the span of several months or few years– working a couple of teams at a time – but
pretending that he’d do it in a few months is unrealistic.
Driving a change initiative, like driving a car, can only be that fast. After a certain point, a crash is inevitable. The
point is not to go as fast as possible, but to arrive at the destination.
INVOLVING MANAGERS
It is necessary that the CEO sets the expectations for the change initiative. Otherwise, the change initiative will not
be considered a priority and will fizzle out as soon as the CEO mentions a new priority (for example, meeting a
target for the quarter).
The CEO setting the expectations for the change initiative includes at least him sending a company-wide email,
informing every employee of the change initiative, of its importance, of his endorsement, and of his expectations
(e.g. “I expect every manager to attend the training by the end of February, to implement the changes in his team by
the end of April and to improve this and that indicator by X% by the end of June.”).
In the best case, the CEO should also do the following: talk about the initiative during “company-wide meetings” (if
the company organizes any), talk about the initiative during every internal meeting with more than 5 people it
participates to, participate himself to the first batch of training, and talk about the initiative during his at-least-
monthly management walk. Because the CEO time is so valuable, all of these are costly signals, thus effective ones.
Every other manager and supervisor in the company should be expected to do the same: sending a team-wide email
and holding a public presentation about the change initiative stating the expectations for his subordinates, talking
about the change initiative during the meetings with his subordinates and during his Management Walks.
Of course, every manager and supervisor in the company – including the CEO, especially the CEO – is expected not
to let any non-conforming-to-the-change-initiative behavior pass. This should be stated into the expectation-setting
phase.
In particular, attending trainings should be a personal objective of every employee, and failing to attend them
(within a reasonable time frame) should be disciplined. As Silicon Valley entrepreneur Ben Horowitz noted, “no
[team] has time to do optional things. Therefore, training must be mandatory.”
Unless specific systems are set in place to ensure the sustenance of a change initiative over time, its results will
revert back to zero in the space of a few months.
Erosion is a powerful force. Even in a company with great managers, as time passes by, events in which a negative
behavior is let pass will cumulate and will erode any positive behavior that the change initiative will have built.
Therefore, great companies put in place systems to fight erosion.
FIGHTING EROSION
Mediocre companies assume that when a goal is met (for example, the injury rate falls below a given threshold),
attention can be moved elsewhere.
Great companies know that the defaults state is that Operational Culture degrades year after year, and that proactive
effort has to be made to keep it from worsening.
Therefore, great companies exhibit the following two traits. First, they keep talking about the Four Principles of
Operational Excellence even when they do not seem necessary anymore. They keep educating their managers on
them, organizing “refresh training sessions” and they bring them as the main topic of performance review meetings.
Second, they keep placing costly objectives on the achievement of Core Values based goals. A “costly
objective” is an objective that harms both the individuals and the company if they are not achieved. For example, the
company might decide that if a manager does not achieve its safety objective, his career advancements are frozen for
that year. This is a costly objective, because the company risks that the manager loses motivation or looks for
another job in case he fails to achieve his objective. However, because it is costly, it is also effective in shaping
behavior.
Conversely, “cheap objectives” are objectives in which the individual has something to gain if he achieves them but
does not lose anything if he doesn’t. These are bad, because they might incentivize managers to “tactically” forego
an objective in order to achieve another one (e.g., neglecting the safety objective to focus on the production one)[19].
REWARDING
Good managers are unafraid of clarity. They know that, even if a blurry objective seems easier to set, it will
inevitably bring larger problems down the road.
Love for clarity and shamelessness in demanding it are strong predictors of Operational Excellence. They are the
two most important qualities your organization might want to reward, be it with promotions, raises, or simple words
of appreciation.
TRAINING
Mandatory “refresher” trainings should be set at least once a year, to ensure that Core Values, rules and procedures
are maintained at the top of the mind of the employees.
Each manager should be required to organize this at-least-yearly training for all of his subordinates. He might
involve Human Resources or external experts to run them, but he should at least be accountable for his subordinates
attending it and for spending a few minutes at the beginning of the training to set the expectations: what skills
should the attendees learn? What new goals should they become able to achieve?
PEER ACCOUNTABILITY
As organizations proceed in the journey towards Operational Excellence, they will reach a point in which Peer
Accountability becomes possible.
To define Peer Accountability, I will use the words of Patrick Lencioni[20]: “Members of great teams improve their
relationship by holding one another accountable, thus demonstrating that they respect each other and have high
expectation for one another’s performance. […] A team that avoids accountability creates resentment amongst team
members who have different standards of performance […] and place an undue burden on the team leader as the sole
source of discipline [… whereas] the team leader should be the ultimate arbiter when accountability fails.”
Peer accountability necessitates that its employees are able to independently see the importance of procedures and of
Core Values. As such, it is not something that should be introduced nor expected by companies which are still at the
beginning of their journey towards Operational Excellence, in which most employees depend upon their manager to
realize the importance of procedures and Core Values.
Only once most employees (at least 70-80%) are able to independently do so, they will be able to become
interdependent, keeping each other accountable.
This is the Holy Grail of Operational Excellence and, in my experience, a very achievable goal, if one follows
consistently enough the Principles, Best Practices and Implementation Roadmap described in this book.
HIRING
The better people your organization hires, the easier it will be to manage them, the easier it will be for them to
manage complexity and to act autonomously, and the better will the Operational Culture ultimately be.
No matter your role, there are some practical actions you can take in order to improve the quality of hires in your
organization.
Write precise and compelling job descriptions. These documents will be used by Human
Resources to filter candidates and to write job postings. A compelling job posting will do wonders to
interest talented professionals and ambitious graduates.
Create good career plans. Depending on the size of your company, this might be your job, you
might be assisted by Human Resources, or it might be Human Resources’ job. In the last case, it is
your job to ask HR to create good career plans for your hires, because good candidates will demand
them. Career plans should be conditional (i.e., if you achieve this and that result, you will grow in
this direction). Do not accept any “we cannot make career plans” answers from HR; instead, ask
them “what conditions should be in place for this career plan to exist”.
Meet potential hires in person. As their potential future boss, you are the person with the better
perception of whether they will be a good fit for your team. Moreover, you are also the person with
the better chance to influence their decision to join your team.
Do not lie during the interview. Using lies to convince people to join your company will only result
in having to re-hire for the position after one or two years, after the person you lied to realizes your
team wasn’t a good fit for them and either quits the company or enters “I don’t care” mode.
Meet HR and your bosses in person, asking them to recruit the talent you need for your team.
Often, a few words exchanged in person can get them to recommend people they would not have
contacted otherwise.
Ask your subordinates to recommend potential hires. Make clear what the desired traits are – this
is also an opportunity to reinforce what is important.
If you need to hire at least two people per year, hire them together. When hiring a single person,
recruiters tend to fall back on the safest choice, which might not be the best choice. When hiring
more than one person, recruiters are more likely to “take little risks” and hire the talent you need.
Screen for Core Values: refuse any hire who does not believe in your Core Values and in their
uncompromisability. It might be tempting to hire a “mad genius”, but such employees often destroy
more than they create.
Keep a good team atmosphere. This does not mean perks and events, but an environment of
fairness and respect. It will make it more likely that your subordinates recommend good hires or
spread good words about working at your company.
Instead of conducting exit interviews asking people who left your team why they did so, ask
them these questions while they still are your team members. For example, in a one-on-one
meeting, a good question might be “if you were to leave the company over the next few years, why
would it be so?”
WHAT TO DO NOW?
Now, the time comes for you to implement your learnings from this book into your company.
Have confidence, in yourself, in the Four Principles and in the Eight Best Practices.
If you will be constant and relentless in their application, results will follow.
…
The author, Luca Dellanna, spent years consulting corporations in Europe and Asia. If you would like him to help
you or your company with an initiative to improve the Operational Culture of your organization, do not
hesitate to email him at Luca@Luca-dellanna.com
If you would like to purchase multiple copies of this book, to share with your colleagues, bulk or corporate pricing
can be arranged. Please email the author and his staff at the address above.
If you would like to learn more about the contents of this book, you can sign-up to the author’s newsletter: Luca-
dellanna.com/newsletter.
…
All the best for your journey towards Operational Excellence!
Aftermath
If this book has been useful to you, please recommend it to your friends and colleagues.
It would mean a lot to me if you wrote a review on Amazon, on Gumroad or on Goodreads, depending on which one
is easier for you.
Writing a review or recommending this book would make my day.
…
I write about one book a year. If you want to be notified of my new publications, you can subscribe to my newsletter
at luca-dellanna.com/newsletter.
I also regularly write on Twitter. Contrary to many authors who use it only for promotion purposes, I tend to reward
my readers’ attention, rather than consuming it. You can follow me on twitter.com/dellannaluca
If you have any question, do not hesitate to email me. My address is Luca@Luca-dellanna.com
I hold weekly and monthly sessions (face-to-face and over the internet) with some of my clients, in which I help
them advancing their career and personal life beyond the advices provided in this book. If you would be interested to
join, don’t hesitate to drop me an email.
…
To the next book, and good luck changing the Operational Culture of your organization and achieving Operational
Excellence!
About the Author
An automotive engineer by training, after having led large teams and consulted for large
multinationals, Luca quit his corporate job to become an independent researcher and author and dedicate his career
on shedding light on the topic of emerging human behavior. Luca believes that this topic is essential for preventing
human suffering, especially as the scale of our civilization keeps increasing.
After having lived in Spain, Germany and Singapore, Luca recently moved back to his hometown of Turin (Italy).
He spends his days between exercising, consulting, investing and conducting his independent research from his
home, a coffee bar or a park.
A few days a month, Luca also consults corporations and individuals that want to improve their businesses. Once
per year he teaches a Risk Management module at Genoa University and runs a few private intensive courses for
entrepreneurs, operations managers, plant managers and CEOs / COOs.
On the next page, you can read about Luca’s other books.
Luca writes regularly on Twitter (@DellAnnaLuca). You can visit his professional website and blog at www.luca-
dellanna.com. You can also contact him at Luca@luca-dellanna.com
You can show your support to Luca by recommending this book to your friends or colleagues, in case you
appreciated its contents, by leaving a review on Amazon / Gumroad / Goodreads, or by contributing to his cause on
Patreon (patreon.com/dellannaluca).
Other books
by Luca Dellanna
Luca’s books can be ordered on gumroad.com/dellannaluca or on amazon.com
“Luca’s book was so helpful to my work. Opened my eyes up to some more reasons why change is so hard.”–
Chris Murman
At a first look, human behavior appears as an inexplicable mess. Why do we behave irrationally? Why do I behave
irrationally? Why is it so hard to change? What is happiness and why does it seem to escape us?
The Control Heuristic offers a new perspective to answer these questions and provides a guiding light to shed the
darkness of the subconscious resistances that prevent us to behave like the man or woman we want to be.
This book is for parents, friend or anyone related to someone with Autism.
This is for neurologists and psychologists to help them understand the world of ASD.
This book is for people on the Spectrum, to help them understand themselves.