From Suits to Steel-Toes: Why Shop Floor Harmony Builds Manufacturing Gold
January 6, 2025
OPINION By Swathi Mohan, Founder of Leanacle Inc.
Why engagement on the shop floor is instrumental for running a successful manufacturing business
Boeing reported a loss of more than $6 billion in the 3rd quarter of 2024. New CEO Kelly Ortberg emphasized that he wants to “reset” management’s relationship with labor so we don’t become so disconnected in the future. Click here to read the related news article.
Among other problems plaguing Boeing, the most notable is the labour strike of its 33,000 machinists. A quick Google search reveals that Boeing isn’t alone, labour protests among Kaiser mental health workers, Canada Post workers, US port workers, and Montreal dockworkers are some of North America’s most notable issues arising from strained relationships between management and workforce in the current time.
Ortberg brings attention to a very critical albeit often overlooked factor in the success of a company. A positive engagement between management and employees. If there is no alignment between the makers of the strategic goals and the teams that implement them, a disconnect arises. Not addressed in a timely manner, this disconnect can lead to adverse effects on the business.
How can we bridge the engagement gap on the shop floor? Where management and frontline workers are physically separated, wear different types of clothing, and work in vastly different conditions? Frontline workers often face harsher environments, dealing with high noise levels, dust, oil, fumes, metal shavings, hotter temperatures, and physical strain. Management, on the other hand, may be oblivious to the physical demands of the frontline workers’ daily tasks, as they focus on the heavy lifting in the thinking realm—handling day-to-day tactics and long-term strategic planning.
This disconnect, where employees may not fully appreciate management’s mental efforts and planning, while management may not fully grasp the physical toll on workers, can lead to a gap in understanding each other’s contributions.
Would it be naive to think that four quarterly meetings, a Christmas party, a Thanksgiving lunch, and a summer barbecue are enough to truly bridge this gap? Do you think that monthly engagement activities between management and employees would make a meaningful difference? These events are mostly one way communications from management to employees.
What if there was a way to provide a voice to the employees as well as generate a return on investment?
Now are talking.
There is a proven, practical way to achieve all of this—not only bridging the gap but also driving operational efficiency by uncovering hidden opportunities on the shop floor with the insights from those adding value every day.
COMMWIP Events: Turning Insight into Action
What if the key to unlocking hidden efficiency on the shop floor lies with the very people who operate it daily? COMMWIP Events tap into the insights of frontline workers while addressing the seven wastes—Correction, Overproduction, Motion, Material, Waiting, Inventory, and Processing.
These events aren’t just about training; they’re about creating a dialogue. Through interactive exercises and real-world problem-solving, employees become active participants in transforming their workplaces. The results speak for themselves—one SME uncovered over $260,000 in cost savings while boosting employee morale and driving operational improvements.
When the gap between management and workers narrows, innovation flourishes, and efficiency becomes second nature. Can your organization afford to overlook this untapped potential?
Key Note from the Author
Swathi Mohan, Founder of Leanacle Inc
Still unsure about the impact of shop floor engagement? Try this simple yet powerful exercise: Take just 10 minutes today to ask each of your team members, “What’s one thing that could make your work easier or more efficient?” Don’t offer solutions, just listen. By the end of the day, you’ll likely have at least one actionable idea that can drive meaningful improvement. If that’s the case, imagine what could happen if you tapped into the ideas and insights from every employee across the shop floor. The potential for improvement is right in front of you—waiting to be unlocked.
Swathi is a former Toyota engineer and founder of Leanacle, where she helps automotive SMEs unlock “profit-boosting efficiency.” She says her clients have seen up to 30% revenue growth in just 90 days by leveraging her expertise in uncovering hidden opportunities on the shop floor.
