Employee Engagement: Making it happen for the Customer

I've mentioned unions before in previous posts, and how some folks find unions to be an obstacle to getting things done.  This week, I'd like to give you another example of a success story from a unionized plant.

At the first B2B manufacturing business I worked for, whenever our general manager was going to be away on vacation, he rotated the job of assuming his role among the members of the management group.

Eventually it became my turn to run the morning production meetings and coordinate production schedules and customer orders for a week. Things started out being very much a routine.

We had an order in house for a new product we were doing for the first time for a new customer my team had been developing.  It wasn't a complex product - just a foil lid for a major yogurt producer - but our production team encountered a serious problem.  The foil we had received to run this order had some significant quality issues that adversely impacted how easily we could run the product on our presses and downstream operations.  It wasn't something we could easily replace.  The lead time for this particular grade of foil was 16 weeks, and the customer's purchase order required it to be delivered the week I was in charge.

Our production manager suggested running the order on an older press that wasn't used much, but we had only a couple of operators who'd ever been trained on this press.  He suggested we ask for volunteers to put together a crew to run this order.

The union assisted us in assembling a crew for this old press and managed to finder an operator from among their membership who had once run this particular piece of equipment.

We met with the crew and explained the challenges to running the job and offered whatever help we could.  They agreed to give it a try.

Not only did they manage to run the order, we also managed to deliver it on time to the customer.  The order took longer to run than we would normally have planned, but the job needed to be run slowly so the press crew could maintain control over the substandard foil they were running.

At no time was the customer aware of the problems we had in producing their order.  The product ran fine on their lines.

At our next communications meeting, the management team recognized the crew who ran the yogurt lid job, and they got lots of cheers from their union mates - and a lot of respect from our management team.

In this case, the men on that crew wanted to demonstrate their skill in running a very challenging job.  None of them wanted to let the customer down.  They came through without the traditional union-management rhetoric.  it was just one instance in which union and management showed they could both be on the same side - the side of the customer.

Employee Engagement: Are Unions Really a Barrier?

Ask most people who work in manufacturing about how they feel about unions, and you’ll get mostly negative responses.

Unions have rules that are counterproductive. They protect poor or lazy employers. 
They’ll strike at the drop of a hat.  They result in higher labor rates.  Union people are antagonistic.

In my career, I‘ve worked in both unionized and non-unionized plants and had equal success in both. 

When in moved from CPG into B2B, I moved from one company with a history of labor woes to another. At my previous company, the plant employees had struck about a month after I’d joined.  At my new employer, I attended my first communications meeting in the first month.  The union representatives were extremely outspoken and confrontational with my boss, the general manager.  At my previous company, the plant was in a different city from our where our offices were located, so I was relatively insulated from the conflict during the strike there.  This time, I was seeing the result of years of poor labor relations first hand.  It was very unsettling.

Our management team overcame the labor relations issues at this company by devoting a portion of our time to being on the plant floor and to becoming approachable so the employees felt comfortable coming to us with questions or issues.

My next employer also was a unionized plant, though I never really noticed the presence or influence of the union when I was on the plant floor.

My sales team and I had been working on developing a new customer in the US. We had provided them sample material.  They never ran it.  I took their sales manager out on sales calls to see if we could jointly develop a new application for the customer’s product.  The project didn’t move forward, but at least we were able to communicate better, though they still had not found time to run our sample material.

It turned out the customer was planning to exhibit at a major industry trade show (as was my company) and I contacted the sales manager to suggest to him it might be a good idea to hand out some samples of their product at the show, and that we’d be happy to supply the material.  I’ll never forget his response.

“Ron, we have four other suppliers for our films and we still haven’t gotten around to qualifying the samples you provided.  However, none of those other suppliers offered to supply film for the samples we wanted to run.  Consider this your first order with us. And please bill us we couldn’t have you provide the film at your expense.”

We wanted to make a really good impression on this customer and provide him a first class product.  I asked our plant manager if I could meet with the operators who would be running the customer’s order.

I told the operators of our goal on this order and asked them how they wanted to run it.  What kind of printing plates?  What kind of inks? Which film supplier to use?  It wasn’t a very long meeting, but I came away feeling like we had a clear plan on how to produce this order.

When the customer received the order (on time, by the way), he called up to complain.

“We aren’t going to pay for gravure printing (a higher-resolution, more costly process than flexography). This job was supposed to be done flexo.  We need flexo printed film ASAP to make the show”

I explained to him, over the phone, that we had definitely used the flexo printing process on his order and that there would be no change in the price.  I asked him to get a magnifying glass and take a close look at the printing, and pointed out to him the characteristics that verified the printing was flexo.  The customer responded,

“Well, this is the best damn flexo printing I’ve ever seen!  I’m impressed.”

The trade show was a huge success for the customer.  His samples were well-received.

I also conveyed to the crew that ran his order the comments he’d made.  They loved it and you could see the pride on their faces.  They knew they’d done a great job.

Did I remember to mention this crew was all union?  I can only see how these guys put aside management-union bias to show off their skill.  And I never heard a negative word from the union local about meeting with their people or working with them.  We all won that day.

The VALUE of SKILLS

When I was in high school, we had three academic streams. There was the truly academic stream for students destined for university. There was a more occupational stream for those students whose goal was simply to get a high school diploma. Then there was the 2-year occupational stream, with a focus on trades.

I trust you can sense a hierarchy of some kind in the descriptions. There certainly was among the students, with the university-bound students looking down on the OC-squad, as they were called, as somehow inferior.

How things change!

When I was in school, as most other kids do, I took shop – and was terrible at it. I’m left-handed. My father didn’t really have a shop at home to practice, and I think I’m not especially mechanically inclined – hard to admit for an engineer!

When I moved into industrial/B2B marketing, I spent increasingly more time in the plant trying to understand how things were done.

I found I came to admire the skills among the personnel on the shop floor.

Pressmen who could make fine adjustments on a $5MM printing press to get just the right color. By eye, they could tell whether an image was too warm (red), too dirty (black) or too cool (blue).

Gluer operators who could transform a die-cut sheet into a complex carton. They had to work out how to make each fold and to do it at as high a speed as possible.

Technicians who could fix a laptop, or build a plasma generator or get your car started – sometimes all of these in the same day.

Carpenters who can make perfect joints, or get a smooth finish on a wood project.

Plumbers who fix leaky toilets, install new pipes and faucets (without leaking).

In the neighbourhood where I live, we have a mix of “professionals” – i.e., lawyers, accountants, etc. – as well as some very well off trades people. The trades people are mostly contractors who are kept busy doing renovations on high-end homes, and are being rewarded handsomely for their skills.

I now see ads promoting the benefits of entering a trade. The school system used to be biased towards developing students for university and failed to produce enough trades people to meet the growing demand in an era in which the long-term skilled workers were retiring or leaving the system.

I play in a blues band, and what I see in this is that we each have our respective instrument to play and, if we all do our part, it sounds wonderful. Notwithstanding the occasional one-man-band busking on the street, each of us has to be proficient in his instrument. No one of us could do it all. We learn a little bit about each of the other instruments – not so much to become experts, but to understand the language unique to each instrument so we can make intelligent suggestions about what might work.

The bottom line is we ALL have our roles to play in making the organization work. It really is hard to say that one role is more important than the others. Despite what accountants might try to do to monetize the value of each job role, the truth is that if one job is not being done well, it can ruin things for the rest.

So let’s respect what each other has to contribute and help them do the best job they are capable of. All of us will benefit.