One inch higher on the left and the magnetic white board would be level. It had been the subject of much speculation on the shop floor that morning. There were several theories floating around, but no one had correctly guessed what the boss had in mind.

While the shop floor was organized according to a logical work flow, production had gotten further and further behind. The right jobs were late, the wrong jobs were early.

Last Friday, the boss had taken an informal poll. “George,” he said, “tell me, how do you know if we are ahead of schedule or behind schedule?” It was a fair question, but one that George did not know how to answer. “Well, boss, I guess if we were behind schedule, someone would come out here and tell us.”

It was an interesting response, seeing as how the floor was running only 28% on-time delivery. The boss walked over to the foreman’s office, leaned in and asked, “Say, John, when we are behind schedule, which I know is most of the time, do we ever tell anyone out on the shop floor?”

“Oh, no, boss, if we did that, they might get discouraged and quit.” Another interesting response.

You see, the boss had just heard of an experiment in a plant where they simply published production numbers on a daily basis to everyone in the plant. Every time there was an improvement over the previous day, the manager would circulate and thank everyone. No bonuses, no pizza, just a complimentary remark. The slow group in the plant improved from 83% efficiency to 87% efficiency. The fast group, however, improved from 96% efficiency to 162% efficiency (62% beyond predicted capacity.)

One inch higher on the left and the magnetic white board would be level. I wonder what your numbers would be. -TF