Here is a situation in which the production manager was so preoccupied with getting the physical output that he did not pay attention to the people through whom that output had to be achieved.
Because human skill is so vital a part of everything the administrator does, examples of inadequate human skill are easier to describe than are highly skillful performances. Perhaps consideration of an actual situation would serve to clarify what is involved:
When a new conveyor unit was installed in a shoe factory where workers had previously been free to determine their own work rate, the production manager asked the industrial engineer who had designed the conveyor to serve as foreman, even though a qualified foreman was available. The engineer, who reported directly to the production manager, objected, but under pressure he agreed to take the job "until a suitable foreman could be found," even though this was a job of lower status than his present one. Then this conversation took place.
Production manager: "I've had a lot of experience with conveyors. i want you to keep this conveyor going at all times except for rest periods, and I want it going at top speed. Get these people thinking in terms of 2 pairs of shoes a minute, 70 dozen pairs a day, 350 dozen pairs a week. They are all experienced operators on their individual jobs, and it's just a matter of getting them to do their jobs in a little different way. I want you to make that base rate of 250 dozen pair a week work!" [Base rate was established at slightly under the 75% of the maximum capacity. This base rate was 50% higher than under the old system.]
Engineer: "If I'm going to be foreman of the conveyor unit, i want to do things my way. I've worked on conveyors, and I don't agree with you on first getting people used to a conveyor going at top speed. These people have never seen a conveyor. You'll scare them. I'd like to run the conveyor at one-third speed for a couple of weeks and then gradually increase the speed.
I think we should discuss setting the base rate [production quota before incentive bonus] on a daily basis instead of a weekly basis. [Workers had previously been paid on a daily straight piecework basis.] I'd also suggest setting a daily baste rate at 45 or even 40 dozen pair. You have to set a base rate low enough for them to make. Once they know they can make the base rate, they will go after the bonus."
Production manager: "You do it your way on the speed; but remember it's the results that count. On the base rate, I'm not discussing it with you; I'm telling you to make 250 dozen pair a week work. I don't want a daily base rate."
Here is a situation in which the production manager was so preoccupied with getting the physical output that he did not pay attention to the people through whom that output had to be achieved. Notice, first, that he made the engineer who designed the unit serve as foreman, apparently hoping to force the engineer to justify his design by producing the maximum output. However, the production manger was oblivious to (a) the way the engineer perceived this appointment, as a demotion, and (b) the need for then engineer to be able to control the variables if he was to be held responsible for maximum output. Instead the production manager imposed a production standard and refused to make any changes in the work situation.
Moreover, although this was a radically new situation for the operators, the production manager expected them to produce immediately at well above their previous output-even though the operators had an unfamiliar production system to cope with, the operators had never worked together as a team before, the operators and their new foreman had never worked together before, and the foreman was not in agreement with the production goals or standards. By ignoring all these human factors, the production manager not only placed the engineer in an extremely difficult operating situation but also by refusing to allow the engineer to "run his own show," discouraged the very assumption of responsibility he had hoped for in making the appointment.
Under these circumstances, it is easy to understand how the relationship between these two men rapidly deteriorated, and how production, after two months' operation was at only 125 dozen pairs per week (just 75% of what the output had been under the old system).
ACTION POINT: Identify and balance the human needs in each work situation.