Time for a revolution

clock with change

(Courtesy of Guest Blogger Alex Pendleton, Big Ideas for Small Companies powered by the MPI Group)

How’s your Change Initiative going? Are you having fun yet?

I’m guessing you answered, “No!”

Why? Because bringing major change to any organization is a tough assignment. Entrenched people, and ideas and habits favor the status quo, and even when that status quo is no longer working, the response of the organization is typically to just give the problem more time. “This too shall pass,” everyone says. “We’ve been through rough times before, and this is no different. What worked then will work now.”

But sometimes it IS different. Sometimes, the organization has quietly aged in place while the world around it has changed to the point that what worked before will NOT work now. Sometimes, what’s needed is a revolution.

For some time, I’ve been involved with two organizations – a manufacturing company and a non-profit – both of which have faced this dilemma, and it fascinates me how much these very different organizations have in common

The manufacturing company was living in the past. It had a dominant position in a niche market, but that market had been slowly shrinking for decades, to the point that the 70-year-old factory was badly underutilized and the fixed overhead was being carried by a smaller and smaller base of business. The aging workforce was resistant to change (there was a sign in the foreman’s office reading “When pigs fly,” evidence of his disdain for any new ideas), and rejection of modern manufacturing methods made it impossible to find customers for new work. The necessary changes all required various certifications, but that was regarded as nonsense, a waste of time and money. An attitude of “we’ve always done it this way” prevailed. Once, they cleaned up the place for a customer visit, and were proud of the result. “The place looks great,” they told themselves — but it didn’t. It looked RELATIVELY good, better than it had in years, but of course the customer saw it in the context of a wider world, and to him it looked ABSOLUTELY awful.

The non-profit organization was also well-established and had been in the same location for most of its life. Decades before, they had made a major investment in upgrading their facility, but by now it was obsolete, and the city had grown away from it, leaving it isolated. However, entrenched board members had fond memories of past greatness, and they were determined that the drop-off in interest and financial support was only temporary. It wasn’t. Before long, they faced an existential crisis.

The solutions to these two problems were similar. In both cases, new leadership was brought in and changes were basically forced upon the organizations.

In the manufacturing company, the factory was substantially overhauled and modernized, quality certifications were obtained, and new markets opened up. A lot of people left (mostly by retirement – over a few years the average tenure dropped from 35 years to eight!), and those who stayed were given extensive training.

In the non-profit organization, a new leader was brought in. He had an abrasive personality and seemed hell-bent on offending all of the existing supporters, starting with the largest donors. But by the time the crisis arrived, he had succeeded in persuading a majority of the board that major change was necessary. Ultimately, they sold their building, collaborated with a couple of other organizations, raised millions of dollars, and moved to the city’s thriving downtown.

Looking back on these two sagas, it’s striking how different the picture looks than it did when we were living in daily crisis. In both cases, the consuming issues dealt with people — in one case, trying to get established employees to accept change; in the other, trying to temper the new leader’s troubling management style.

In the manufacturing company, the change was generational. A new, young leader had the vision and the skills needed to move the company forward, but members of the executive team – even new hires – struggled to perform. Operations went through five leaders in as many years before finding the right person, and the sales department went through two. Looking back on board meetings in those transitional years, it’s amazing how much effort went into trying to salvage the wrong person in the job and how quickly things improved when the right person finally arrived. There’s an important lesson there about insisting on top quality in people and not settling for anything less. Peter Schutz, a former leader of Porsche, always advised people to hire slowly and fire quickly. That’s good advice, albeit easier said than done. Once you’ve filled a critical position, it’s difficult to believe that backing up and starting over will be easier than trying to fix what you’ve got — but in retrospect it’s usually a good idea.

In the non-profit organization, the resolution was simpler, though no less painful. We ultimately realized that we had gotten from our exasperating leader all that we could — his revolution was already in motion — and all he had left to offer was his difficult personality. It was time to end the constant conflict and move forward. The new executive is an extraordinary leader and has the enthusiastic support of the entire staff and board. There still are problems, of course – non-profit organizations always face challenges — but the replacement of conflict with collaboration has resulted in a great place to do great work, and exciting innovation has ensued.

In both cases, I wonder if the rosy present would have been possible without the turbulent past. Revolution is frequently necessary, and almost always difficult and unpleasant; but I think it’s important to recognize that difficulty and unpleasantness don’t have to be new long-term realities, but can instead be short-term growth phases. So if your situation needs a revolution – and sooner or later it probably will – realize that it’s likely to be difficult and unpleasant, and that it’s possible that the right team to start a revolution may not be the right team to finish it. What is certain, though, is that once your revolution has succeeded, you’ll have a vast improvement over the status quo.

At least until the next revolution.

Cuyahoga Community College’s Manufacturing Center of Excellence works to fill the skills gap

Tri-C manufacturing center of excellence

In June, I met with Alicia Booker, vice president of manufacturing, and Alethea Ganaway, program manager additive manufacturing & Ideation Station, of Cuyahoga Community College’s Workforce, Community and Economic Development division at the Metro Campus. Booker says, “We take a manufacturing systems approach and not a product approach. We don’t just focus occupationally on the need to fill a gap then three months later the need arises again due to churn.”

For this team, it’s all about workforce development and creating a skilled workforce. More than 3,500 students are attending the workforce programs, including youth, adults interested in a career transitions, students who already have a degree but are returning to upgrade skills, older adults interested in a second career, employees who need additional training for their current role, and job seekers interested in starting a career.

Booker moved to Ohio two years ago from Pennsylvania to accept the position. Ganaway was moved from Tri-C’s robotics program to additive manufacturing in order to write the grant to fund the program. Now, two years later, the fruits of their labor are paying off in the Manufacturing Center of Excellence (MCoE).

Booker says, “We offer a unique brand of training – short-term through two-year degree plus transfer opportunities. Classes are offered in environments that meet the needs of the students and customers — day, evening, weekend, and bootcamp formats, full- and part-time training, and now we can offer onsite training through the Citizens Bank Mobile Training Unit. Our programs are comprehensive, offering exploration and career exposure to students as young as eight years old through our Nuts & Bolts Academy, middle and high school visits (via the mobile unit), and our college credit plus K-12 initiative.”

This is what the impressively outfitted MCoE contains:Tri-C manufacturing center of excellence scanner

  1. A shop that houses CNC equipment
  2. An integrated systems line with Fanuc robots that launched in June 2017 (Students can become a certified production technician in eight weeks, including program automation, PLCs, and visual inspection for quality control.)
  3. A 3D printing lab that houses a Faro scanner and two printers that can print biomedical-grade devices
  4. A PLC training line with both Allen-Bradley and Siemens systems that launched In August 2017 (Students can earn an international certification for Siemens Mechatronics Systems, mainly used by European companies, since there are more than 400 German companies in northeast Ohio, while Allen-Bradley is more common in The United States. Some companies, such as Ford, use both systems in different portions of the plant. The training line includes a PLC station with hydraulic and pneumatic boards and a robotic arm.)
  5. A rover for virtual-reality training and integrated gaming
  6. A Fab Lab, a maker space for community and international collaboration (it houses a classroom; a Techno CNC router; an embroidery machine; a small mill for engraving, heat presses for T-shirts, hats and mugs; a laser engraver; and a vinyl cutter.)
  7. A mobile unit that can go to businesses, events and schools for teaching and demonstration opportunities in a nine-county area that launched in February 2017 (The trailer fits 10 students and instructors; is WiFi, laptop and software equipped; has its own generator; has plugs for different amperages; and can be deployed with electrical, welding, CNC, mechanics and 3D printing equipment. The lab already has been deployed to the 2017 IndustryWeek Manufacturing & Technology Conference & Expo, a workforce summit, Crestwood Local Schools, and Boys & Girls Club of Cleveland.)

According to Ganaway, “The Additive Manufacturing program includes not only 3D printing, but we teach students how to reverse engineer parts, 2D and 3D design, 3D scanning, inspection and other technologies related to additive manufacturing.  Additive manufacturing is not just related to manufacturing; it includes other disciplines, as well, such as medical.  Some of the projects include 3D printing prosthetics for veterans at the VA who are disabled.”

The college offers training by which students can earn college credits and industry certifications. In the welding training, they learn MIG, TIG, and stick welding. Right Skills Now affords students with CNC training in manual and automated machining. They train on Haas CNC mills and lathes, and on Bridgeport manual machines. The 3D/additive manufacturing training is in digital design, and students receive training in multiple 3D printing technologies, including the use of 3D printers, scanners, and other equipment available through the Ideation Station where they can work with a techno router, laser engraver, etc. In Mechatronics, students learn techniques in mechanical, electrical, computerization, and gain an understanding of how these systems work together. Finally, as a certified production technician, students are prepared to begin career opportunities in manufacturing and earn four industry certifications in areas of safety, manufacturing processes and production. This is a hybrid training program that includes training on the integrated systems training equipment to prepare them for occupations in material handling, assembly and production.

To stay connected to industry, the program has several advisory committees made up of industry professionals from the welding, machining, electrical, mechanical, 3D printing and transportation sectors. They also have specific employer-based programs, including First Energy, Swagelok and ArcelorMittal, who have advised the college on customized programs that lead to employment with their companies. Local businesses, such as Cleveland Job Corps, Cleveland Municipal School District, Towards Employment, Boys & Girls Club, Ohio Means Jobs, Ford, General Motors, Northeast Ohio Regional Sewer District, Cuyahoga Metropolitan Housing Authority, NASA, Arconic, Charter Steel, and others, utilize the program’s services.

The program, says Booker, helps to meet the growing demand for a skilled workforce by “working to strengthen the region by supporting the existing efforts of our partners and by addressing the needs we hear from employers for a skilled workforce. We provide a quick response for new skills by developing new programs and training modalities. We also are working with schools and youth-serving organizations to enhance the talent pipeline that industry needs.” She continues by sharing that the most common challenge that she sees manufacturing facing is “the alignment of skills — commonly referred to as the skills gap. The impact of technology on the industry is also a challenge as industry works to keep up with the growth of technology, and we (as a training institution) work to keep up with the projected needs for skilled workers.”

Tri-C manufacturing center of excellence mechatronics