Tag Archives: supervisor

The Shift from Supervisor to Manager

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“Tell me, Joel, in making your transition from supervisor to manager, why do you think things slowed down for you?” I asked.

“The biggest difference,” he replied, “is that I am not dealing with things so much as I am dealing with people. When I was a supervisor, I just made sure material got received, stocked, staged and moved around, that machines worked, and that everybody was at their workstation. Sure, things shifted around and we changed the schedule all the time, but it was easy compared to this. As a manager, things have slowed down, but it’s a lot harder to get things done. It’s more complicated. I have to think further into the future.”

“How far into the future did you have to think as a supervisor?” I pondered.

Joel thought for a minute. He had never considered how far into the future he to think. “Well, as a supervisor, I guess it was only a few months out.  I mean, we had some long lead time items, and sometimes we had to reject materials that were out of specification, meaning the lead time doubled, but even with that, four to five months.  And with people, I just scheduled from the list of people of the team.  Now, I have to look out and see if we have enough people on the list.  I have to decide who is on the team.”

“Tell you what, Joel. The next time we meet, I want you to list out the longest tasks you had as a supervisor. I want to go over that list with you to see if we can make some sense moving forward as a manager.”

Being a Manager, Different From Being a Supervisor

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Joel was not shaking, but he was certainly shaken.

“I just don’t know,” he said. “Since I was promoted from being a supervisor to a manager, things are different. It is certainly not as easy as I thought, a bit out of control.”

“Being new to management is tough. No one prepared you for this, they just promoted you and expected you to figure it out,” I replied.

“And what if I don’t figure it out?” Joel asked.

“Oh, you will figure it out. But that is no insurance that you will succeed. There are a number of reasons that managers don’t make the grade. The first reason is commitment. This is harder than you thought it would be. Being a manager requires a passion for being a manager. Being a manager is a lot different than being a supervisor.”

“You are right about that. Being a supervisor was fun, fast paced, things were always changing and I had to respond quickly. Being a manager, things move slower. I have to think about things. And the worst part, most everything I do is accomplished through other people. Other people are hard to control. They don’t always show up the way I want them to.”

“So, you are facing the first challenge of a being a manager. Do you really want to be a manager? Do you have a passion for it? Just saying yes doesn’t make it so. Why do you have a passion for it?”

Identifying Supervisory Capability

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“When was the last time you walked the floor and talked to the line crew,” I asked.

Denny paused.  He knew it was a loaded question.  “I walk the floor a couple of times a day.  But, I depend on my supervisors to talk to the line crew.  As the Plant Manager, I have a lot of important things that keep me in my office.”

“So, what do your supervisors tell you about the line crew?”

“Mostly, they just complain about this one coming in late, or somebody out sick.  The usual stuff.”

“So, you never actually talk to anyone on the line crew?” I pressed.

“No, if there is a problem, I let my supervisors handle it.  I don’t want to interrupt the chain of command,” Denny explained.

“What happens if one of your supervisor’s quits?”

Denny peered over the top of his glasses.  “I guess I would have to hire another supervisor.”

“And, where would you go first, inside or outside?”

“I don’t know that there is anyone on the line that could step up and be supervisor.  I would just put an ad in the paper, do some interviews and pick somebody.”

“Why don’t you know if there is anyone on the line with supervisory capability?”

How to Miss Something Important in a Candidate Interview

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Kirklin was shaking his head.  “I don’t know how we missed it,” he muttered.

“Missed what?” I asked.

“We hired this guy about a month ago, to be a supervisor in one of our technical areas.  Six guys on his team.  How hard could it be?”

“I don’t know, how hard could it be?” I probed.

“Apparently, pretty hard.  His team’s production is behind and his team members are coming up to me privately and complaining.”

“What are they complaining about?”

Kirklin thought for a moment.  “Just general stuff, doesn’t really matter.  Bottom line, this new supervisor has never supervised a team before.”

“Then, why did you pick him for the job?” I wanted to know.

“Well, he was a supervisor at his old job.  I mean, he had a supervisor title.  Today, I asked him how many people he had on his team.  Turns out, he didn’t have a team.  He supervised a machine.”

“How did you miss that in the interview?”

“I guess I never really asked THAT question,” Kirklin replied.

How to Smile and Train Slow

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“I hope you know what you’re doing,” said Charlie. “You are going to lose eight hours of production today.”

My plan was to rotate eight operators off-line for one hour each. In that one hour, Charlie was going to coach the operator to perform data entry in real-time with a customer on the line. The current method was to take notes on paper and, later, enter the order in the computer. It was a delayed process that created mistakes and missing information.

Charlie was coaching the operators, I was coaching Charlie. Actually, I was training Charlie. Our first subject was Sonja.

“Good morning, Sonja,” I took the lead. “You have completed the training for the real-time data entry and then we throw you back on-line with real customers. I don’t know if that is fair, so today, we have you off-line for an hour. We will do the same work, but the customer won’t be real. In fact, I am going to be your customer, so if you need to stop and slow down, all you have to do is smile and we will slow down.

“Since, I am the customer, Charlie will be your coach. Every time Charlie sees something he really likes, he is going to stop you and tell you about the element you did well. Ready?” Sonja smiled.

“You smiled,” I said. “So, let’s take it slow. You have your phone script, let’s start at the top.”

Sonja started through the script. Twenty seconds in, I stopped her.

“Charlie, we just finished the first few seconds of the call. What were the elements that Sonja did well?” Charlie stared at me, intently. Though I had briefed him before we got started, he was still focusing on mistakes. In the first twenty seconds, Sonja had made no mistakes, so Charlie didn’t know what to say.

“Charlie, in the first few seconds, did Sonja stick exactly to the script?” Charlie nodded. “Then, tell Sonja what positive element she accomplished by sticking to the script.”

So, Charlie talked about consistency. And we went on, stopping every few seconds, so Charlie could make a positive comment about Sonja’s performance. The first call took 15 minutes. The second call took 12 minutes. The third took 8 minutes. The fourth took 7. Then 6 minutes. The last two calls hit our target at 4 minutes, and then we had coffee.

Why Train When There is No Time

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“Look, we have a certain amount of work that has to be done around here and I can’t just sit by and watch these guys go so slow. They just don’t get it. I have been working with them for eight months.” Charlie stopped. He shook his head. He had been trying to get his telephone operators to go paperless. It wasn’t working.

“Did you know that you are a really good phone operator?” I asked.

“I know. I did it for six years before I came over to work here. I am the best. I just wish there was ten of me. This is a busy place.” Charlie seemed off the defensive, now.

“Why do you think the coaching is failing?” I asked.

“Oh, it’s not the coaching,” said Charlie. “It’s the training. We just have so much work to do that we don’t have time to train. It’s fast paced. These guys just can’t keep up. And the turnover on my team is killing me.”

“Charlie, what happens when a race car driver takes a curve too fast?”

“What?” said Charlie, off guard. He wanted to talk about operator through-put, and I was talking about race cars.

“Let’s say there is a straight-away coming up, where we can really blow it out, but we have to negotiate a turn first. What happens if the driver takes the turn too fast?”

“Well, he’s going to hit the wall.” Charlie responded.

“Charlie, sometimes, you have to slow down to go fast.” I waited to let that sink in. “Charlie, tomorrow I want you to schedule one operator per hour to be off the phones and back into coaching. See you at 8:00 sharp.”

How to Look at the Size of the Role

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“So, as you see me struggle with my new role as a manager, what do you see as my biggest challenge?” asked Joel.

“The biggest mistake most companies make is underestimating the level of work required for success in a role. The biggest mistake most managers make is underestimating the level of work required in a task,” I replied.

“And level of work can be measured by looking at the Time Span of the task?”

“And don’t be fooled.  For a manager, the task starts earlier and the completion time is much later than for a supervisor.  A supervisor makes sure the production gets done.  A manager creates the system in which production is done.  It’s a much bigger job, a higher level of work.”

How to Calibrate the Time Span of a Task

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Joel laid the list on the table. “It’s weird,” he started, “there were some obvious things, but there were some other things that were more interesting.”

I had asked Joel to make a list of tasks that he had performed as a supervisor and to identify the time span of each task.

“For example,” he continued, “I ran a rolling production schedule out for six weeks. So at any one time, I was working six weeks into the future. But there were some other tasks that were longer than I thought.

“I was in charge of raw materials. We would get in shipments of plastic parts that had to be inspected. There was a time when a whole boatload of parts was defective. In the short term, I had to really move around the production schedule to keep things moving. But in the long term, I had to work with the vendor on getting replacement parts. I had to figure out what we needed to keep in production, then to build back our raw goods inventory.

“Finally, I had to spend time figuring out what the problem was with the parts, working with the vendor to solve the problem. Turns out, there was a bad batch of resin from another supplier. Because of the problem, the resin supplier actually went out of business and our vendor had to find a new source. I know it was his problem, but I had to work with him, trying out and finally certifying a new resin supplier so our parts would hold up. That whole process took five months and my manager expected me to handle it without a lot of direction from her.”

“So the time span for that project was about five months?” I asked.

“Yes, you could call it five months.  Most of the time it is easy, averages out to be fairly short in time frame.  But, when it’s hard, I have to look out further.  Even when it’s hard, it’s still part of my job.”

“So, now in your new job, as a manager, what are some of the tasks that you will be responsible for and what is the time span? Take a look at your job description and meet me back here tomorrow.”

Time Span of Tasks of a Supervisor vs. a Manager

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“Tell me, Joel, in making your transition from supervisor to manager, why do you think things slowed down for you?” I asked.

“The biggest difference,” he replied, “is that I am not dealing with things so much as I am dealing with people. When I was a supervisor, I just made sure material got received, stocked, staged and moved around, that machines worked, and that everybody was at their workstation. Sure, things shifted around and we changed the schedule all the time, but it was easy compared to this. As a manager, things have slowed down, but it’s a lot harder to get things done. It’s more complicated. I have to think further into the future.”

“How far into the future did you have to think as a supervisor?” I pondered.

Joel thought for a minute. He had never considered how far into the future he to think. “Well, as a supervisor, I guess it was only a few months out.  I mean, we had some long lead time items, and sometimes we had to reject materials that were out of specification, meaning the lead time doubled, but even with that, four to five months.  And with people, I just scheduled from the list of people of the team.  Now, I have to look out and see if we have enough people on the list.  I have to decide who is on the team.”

“Tell you what, Joel. The next time we meet, I want you to list out the longest tasks you had as a supervisor. I want to go over that list with you to see if we can make some sense moving forward as a manager.”

What It Takes to Move from Supervisor to Manager

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Joel was not shaking, but he was certainly shaken.

“I just don’t know,” he said. “Since I was promoted from being a supervisor to a manager, things are different. It is certainly not as easy as I thought, a bit out of control.”

“Being new to management is tough. No one prepared you for this, they just promoted you and expected you to figure it out,” I replied.

“And what if I don’t figure it out?” Joel asked.

“Oh, you will figure it out. But that is no insurance that you will succeed. There are a number of reasons that managers don’t make the grade. The first reason is commitment. This is harder than you thought it would be. Being a manager requires interest and passion for being a manager. Being a manager is a lot different than being a supervisor.”

“You are right about that. Being a supervisor was fun, fast paced, things were always changing and I had to respond quickly. Being a manager, things move slower. I have to think about things. And the worst part, most everything I do is accomplished through other people. Other people are hard to control. They don’t always show up the way I want them to.”

“So, you are facing the first challenge of a being a manager. Do you really want to be a manager? Do you have a passion for it? Just saying yes doesn’t make it so. Why do you have a passion for it?”