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Companies who provide good incentive programs for their production crews and first line supervisors enjoy benefits far beyond just direct productivity increases, spectacular as those can be: Improvements in the 50% range are not uncommon. On top of that, though, such a program can tap into a resource that lies dormant in far too may companies: The day to day, down to earth, expertise of the hourly employees who do the actual work that the company eventually gets to collect money for. OK, they may not have even a High School education, but I have found them to be smarter than I expected, particularly about what they do all day long. Of course, without an incentive for them to apply their knowledge productively, many company owners and managers tend to view these folks as the source of some of their most vexing problems: Absenteeism, turn-over, lost time accidents, complaints and grievances, poor quality, low output, and so on and on. Even a well designed incentive program will not completely eliminate all of these problems, but it can make huge improvements. Here are some examples.
Let's say a company has a (properly designed) IC program which compares actual output against a reasonable standard, and distributes, say, one half of the amount saved by beating the standard among the crew members, including their direct supervisor, chief, foreman, whatever. We'll talk some more about how to do that in a minute, but just look at the things that happen right away: There is no longer any need to watch people to make sure they are working, because everybody knows that the laggards hurt the crew as a whole, so they watch and encourage each other. Social pressure is more effective than nagging by the supervisor any day. Quality improves because it is costly to do things over. Crew sizes tend to be more effective: I have had crews ask for members to be transferred to improve the output per man hour charged. Occasionally, conversations actually turn from sports and sex to ideas for doing things better, faster, easier. Morale improves: Working to beat a standard is much more fun than just putting in time, and the bonus payments, when they come, are like "found" money. Of course, turn-over drops as morale improves.
A good IC program also helps with supervisory training, because it lets first line supervisors acts as Leaders and Coaches instead of Naggers and Pushers. They can do their job just by helping the crews maximize their bonus earnings, telling them how "we" are doing, pointing out what can be done to improve, addressing and correcting problems as they arise, and generally being experts on the program who can answer questions and deal with concerns. So they learn to be much more effective supervisors than they would otherwise be, and, in the IC program, they have a tool that helps them be effective.
What's more, the crews will also be checking on their supervisors: They want the number of hours turned in to be as low as possible, so they do not want any of this checking a friend in early or out late or, as sometimes happens, reporting of entirely fictitious hours. In effect, then, a good IC program can also act as an inexpensive but highly effective production management control tool.
To provide all these benefits, the production incentive program must have the confidence of the production crews. They must absolutely believe that, if the make the effort, if they do well, bonus awards will follow like night follows day. If they do not, they will view the program as a slot machine - it pays off if you are lucky or the boss feels like it, effort and performance have nothing to do with it. Obviously, slot machines do not provide incentives, and so do not yield the benefits of a good IC program. They may actually be counter productive by generating bad feelings and ill will.
The crews will believe in the program if they and their supervisors understand it, and, above all, believe that the standards against which they are measured are reasonable and achievable. So - the standards should be as simple as possible, should be explained thoroughly and clearly, as many times as may be necessary to achieve complete acceptance. The source of the explanation should be the most credible available, preferably someone the crews accept as a real authority on their work. Do stay away from anonymous sources like "the computer", "acconting", "the office", "the bid price". If neceaary, a little hocus pocus with stop watches and clip boards can be helpful.
Once the program is under way, there must be opportunities for feed-back and exchnage of ideas for two equally important reasons:
First, to protect the credibility of the program. Supervisors must be able to get management to change any standards that prove to be incorrect, or at least get a good explanation for standards that just look wrong. Further, their crews must believe they can do that, so the supervisors need to be able to come back with answers.
Second, to make sure that good ideas from the field are utilised: Perhaps the company's pricing structure does not adequately reflect production difficulties; perhaps quality issues are routinely over sold or under sold; perhaps customers are made unrealistic promises; perhaps not all relevant information is obtained during the sale; perhaps materials obtained form some suppliers are unrealiable; and so on. There are probably dozens of production details that should beneficially called to top management's attention. With the IC program, the crews now have an incentive to do so.
Finally, changes in the IC program should be handled carefully and thoroughly. Modifications should be predicted when the program is first introduced, perhaps by announcing reviews at stated intervals. Then, when adjustments are needed, let's face it, the crews are going to be suspicious if the program has treated them well up to that point. So, the adjustments need to be explained with just as much care and concern for credibility as the original presentation.
A good production IC program can have a decisively positive impact on a company's profitability and competitive prowess, so it is well worth the time and effort required to launch it and work with it. On the other hand, a program that is poorly designed and improperly implemented can actually be worse than none at all.
If you would like to talk about this subject some more, feel free to send me a message at jurgenringer@iib.ws
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