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COACHING TEAMS FOR SUCCESS
IN CELLULAR MANUFACTURING
By Gary Conner
THE FABRICATOR - Article reprinted with permission from the June
1996 issue of The Fabricator
Selecting a Team Coordinator
Training the Team Members
Insights About Successful
Each weeknight started the same. Rick and I arrived early to work,
armed with the tools of the trade—calipers, protractors, and
bend allowance formulas. We each brought years of experience to
the task at hand, well aware that knowledge was power and sharing
with others little more than needed to get the job done, holding
back subtle details which could provide the needed edge in this
In another time, it might have been high noon, but we squared off
at 5:00 p.m. waiting for our chance in front of the machine for
the opportunity to show up the other shift. With our livelihoods
at stake and our family futures in the balance, the 5:30 shift change
signaled the end of one daily serial and the beginning of the night
To succeed in our mission, we would have to jointly outperform
our day-shift counterparts while maintaining the delicate balance
and competitive distance that would afford us operator autonomy
and a record of individual performance, ensuring that we would be
long remembered in the mythical Press Brake Hall of Fame.
The Olympics of sheet metal began anew each night, where we were
only as good as the last pallet of parts off our machines.
Where the parts came from or where they were going made little
difference in this process-driven facility layout. A departmental
press brake goal of four bends per minute overshadowed any concern
about line balancing, small lot sizes, pull systems, or Kanban replenishment
Each day we attempted to better the competition, both within and
outside our company. The goal was clear: earn our stars on the "Fabricator's
Walk of Fame." This was friendly competition at times, but
with serious undertones.
In what now seems like an instant, our situation changed. We found
ourselves promoted and placed in charge of directing the efforts
of other people, making decisions, setting schedules, and determining
I was first charged with leading a team of "weekend warriors,"
a crew working 12-hour days on Friday, Saturday, and Sunday. Rick
was placed in the role of supervisor for an entire fabrication facility.
Over time, Rick and I had opportunity to set up a number of work
teams together. We learned through shared experience the value of
losing departmental single-mindedness; we had to change our patterns
and habits associated with functional process flows (departments
set up around specific equipment or processes). We soon came to
recognize the folly that is internal competition, and we became
aware of the myopic focus so prevalent in traditional manufacturing
Our roles came with a number of serious drawbacks. We were charged
with directing teams of un-crosstrained individuals who showed up
every day and produced relatively adequate product. While we were
happy to be promoted, at the same time we were also keenly aware
of a drop in productivity as we stepped away from the machines.
It was easy to fall into the trap of just doing it ourselves rather
than coaching others to be more capable.
Rick became the production manager for an entire facility, and
I was assigned the job of "in-house coordinator" for a
company's "world-class" manufacturing program. Spending
our time training and setting up new teams, we had a number of successes—as
well as a few failures.
Where we experienced failures, we learned, and a recurring lesson
was that when teams are bossed instead of coached, or when they
are left on their own instead of being provided a clear vision and
measurable goals, their success is limited, if not nonexistent.
We had to help the teams overcome many of the same negative patterns
and habits we had been encouraged to lose.
This process was at times slow and frustrating. Wanting to see
change rapidly, we ran the risk of driving people away rather than
fostering an environment of positive momentum. However, when the
adoption of these concepts moves too slowly to show management that
progress is being made and that productivity improvements are just
on the horizon, the tendency is to call the exercise a failure of
the team, rather than to look at the training, vision, and level
of coordination provided to the team.
I have come to appreciate that this is the scenario
many new managers who see the positive enefits associated with Just-In-Time
(JIT) technologies and so-called "self-directed" work
teams will face.
Selecting a Team Coordinator
To assist teams in making an effective transition, some coaching
and assistance is required. The first in many critical steps is
the process of selecting a team coordinator. Closing the gap between
being a great machine operator and a competent team coordinator
takes time and patience. It is also critical for management to acknowledge
the fact that a great machinist does not necessarily make a great
coordinator in every case.
With the advent of cellular manufacturing teams, it is becoming
more commonplace to have skilled machine operators placed in the
position of team leader or coordinator. Even self-directed work
teams need a coordinator or spokesperson.
The methods used when selecting a coordinator often determine both
the short-term success of the person selected and the long-term
success of the team. Choosing a coordinator is often a task performed
by management—a decision that they expect the teams to endorse.
Why? From management's perspective, the team is paid to follow
orders, and the ability of the team to make good decisions about
such matters is in question. In the infancy of the team's development
this may truly be the case, but as a team (or steering team) matures,
with proper direction, the team can be helped to understand the
importance of making good business decisions.
With proper coaching, a team will often be able to leave personal
feelings aside long enough to base decisions on facts and data.
A helpful strategy is to have a skilled facilitator lead the team
through the following steps. This process can be used when selecting
a team coordinator or leader (or for weighing out the value of any
- Have the team list the great leaders in history.
- Have the team identify the positive characteristics of each
- Have each team member then assign a value (from 1 to 5) to
each characteristic, relating to how important it would be for
the coordinator to have this attribute.
- Have the team identify and list those personnel nominated or
interested in being considered to serve as team coordinator. Include
any suggestions by the management team.
- On a grid, list the attributes in valued order of importance
(see Figure1). One by one, have each team member objectively discuss
the candidates' qualifications in regard to each attribute.
- Avoid voting, but allow each team member to have points totaling
two times the number of candidates to use as a rating/weighting
tool. Example: If there are 3 candidates, then each member is
allowed 3 x 2 points, or 6 points total, to assign to the three
candidates. No more than half (in this example, 3) can be assigned
to any one person.
The result of each poll (which can be anonymous) is averaged, and
the process is repeated for each characteristic. The candidate's
score is then multiplied by the value of the attribute. The columns
are then totaled, resulting in a weighted grand total for each candidate.
The team is thus able to logically, instead of emotionally, select
a team member through a consensus-based process.
Once a person is appointed as coordinator, an adjustment period
to the change begins. Both the coordinator and the team will be
making some adjustments.
The level of commitment to the newly appointed coordinator is usually
greater because no votes were cast, so feelings of "loss"
or that "our choice was not elected" are minimized. Decision-making
by consensus takes a little longer, but the "buy-in" and
implementation periods are greatly reduced.
Training the Team Members
Here, a measure of coaching for both coordinator and team will prove
very beneficial. Short cutting the training of coordinators and
teams is a little like the guys who used to cut across the track
when the P.E. teacher had his back turned. Their performance never
got better, and they had only themselves to blame for cheating themselves
out of greater achievement.
Educating the team members to work together and to think as a business
unit requires them to adopt a new set of values. Some of these values
are learned behaviors, so adopting these values will not happen
by osmosis. Just the discussion of these values can be a potent
opportunity for enhancing open communication and the speed at which
teams work through the group dynamics associated with becoming a
high-performing team. No matter how well the management team understands
and embodies the values, communicating them clearly and distinctly
to the team is critical.
Figure 3 shows a small sample of the values which are critical for
teams to examine, both from a before and after perspective. Understanding
how each member plays a role in adoption of these values places
accountability for success squarely with the team.
This is not rocket science. Instead of looking for a quick fix
to our manufacturing challenges, this author recommends a measured,
logical, well thought-out, time-phased project within which teams
and team coordinators are allowed the opportunity to experience
the implementation of such new values firsthand, along with training
which allows them to be successful.
Some of the recommended training includes technologies for implementation
of cellular manufacturing:
- Fast setup
- Small lot sizes
- Pull systems
- Focused layout
- Load balancing
- Process and product simplification
- Error proofing
- Handling and packaging
- Preventive maintenance
- Collecting and analyzing data
- Effective problem-solving techniques
For team coordinators to be most effective, some additional training
may be required on topics such as:
- Learning the importance of effective leadership.
- Understanding the challenges leadership requires.
- Developing skills in offering and receiving feedback.
- Appreciating the value of group diversity.
- Overcoming resistance to change.
- Learning how to conduct effective meetings.
- Setting performance expectations.
- Dealing effectively with disciplinary issues.
- Understanding conflict resolution techniques.
- Learning to create an environment that fosters initiative.
- Learning the value of coaching versus bossing.
- Understanding adult learning and communication styles.
Insights About Successful
Rick and I have since had the opportunity to assist dozens of teams
on a number of different projects. In every case, the level of success
was directly proportional to the level of training provided to the
Without a clear definition of what the desired outcome is, and
without adequate training and tools provided to meet the challenge,
the teams' results will always fall short. This then sets up a vicious
circle in which no one wants to be a part of future attempts.
Spend the time, then, to pave the way for teams to be successful—first
in methods of selecting leadership for the team, then in educating
the team on what the objectives are, and then in how they can quantify
(measure) their success in meeting these objectives. Celebrate their
successes with them along the way. Encourage them to collect their
own data and to solve problems together for those issues that do
not work so well.
People have an inborn desire to succeed, to be viewed as competent.
Provide people with the right set of tools, and they will generally
exceed the expectation. The success of a high-performing team is
contagious, and the synergy generated by a number of high-performing
work groups can set a company apart from its competition.
Management's willingness to apply adequate training resources and
to let go of responsibility will determine how successful the teams
are in meeting these objectives. The term self directed work team
is a misnomer. There is no such thing. Management has the responsibility
to guide and provide clear vision for teams so that they are not
left to flounder. If management does its part and fosters an environment
of positive change, there can be near-miraculous improvements in
productivity, employee involvement, team cohesiveness, and job satisfaction.
Gary Conner is with Technical Change Associates, Ogden, Utah. Rick
Price, who is mentioned in the article, is Production Manager for
Neilsen Manufacturing Inc., Salem, Oregon.
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