Assembly Magazine logo
search
Ask ASSEMBLY AI
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Assembly Magazine logo
  • TRENDS
    • Ask ASSEMBLY AI
    • Trends
    • News
    • New Products
  • INDUSTRIES
    • Aerospace
    • Appliance
    • DFMA Assembly
    • Medical Devices
    • Green Manufacturing
    • Lean Manufacturing
    • Machinery Assembly
    • Electronics Assembly
    • Automotive
  • TECHNOLOGIES
    • Adhesives & Dispensing
    • Assembly Presses
    • Automated Assembly Systems
    • Manufacturing Management
    • Manufacturing Software
    • Motion Control
    • Screwdriving & Riveting
    • Robotics
    • Test & Inspection
    • Plastics & Metal Welding
    • Wire Processing
    • Workstations
  • AUTONOMOUS & ELECTRIC MOBILITY
    • AEM Magazine Archives
    • Autonomy
    • Electrification
    • Mobility Services
    • Assembly & Testing
    • AV/EM News
  • MEDIA
    • Ask ASSEMBLY AI
    • Podcasts
    • Assembly News Now
    • Assembly TV
    • Webinars
    • eBooks
  • EVENTS
    • Calendar
    • The ASSEMBLY Show
  • MORE
    • Exclusives >
      • Plant of the Year
      • Capital Spending
    • Buyers Guide >
      • Supplier Insights
    • Classifieds
    • Featured Products
    • Newsletters
    • Store
    • White Papers
    • Columns
    • Sponsor Insights
  • INFOCENTER
    • Assembly & Test Solutions
  • EMAGAZINE
    • eMagazine
    • Archive Issues
    • Advertise
    • Contact Us
    • Sign Up
ColumnsLean Manufacturing Assembly

Leading Lean: Keys to Employee Engagement

By Jamie Flinchbaugh
March 26, 2010
Manufacturers have no trouble hanging onto key employees these days, since job opportunities are scarce. But, that hasn’t reduced the need to find new ways to engage people. No matter what type of economic opportunities a company can provide, engagement still plays an important role in employee retention.


Manufacturers have no trouble hanging onto key employees these days, since job opportunities are scarce. But, that hasn’t reduced the need to find new ways to engage people. No matter what type of economic opportunities a company can provide, engagement still plays an important role in employee retention.

However, you can’t just sit back and assign this problem to the human resource department. Engagement must be continuous at the point of activity. The following three elements must work together:

  • Building the right culture that enables and even values engagement.
  • Building the right systems or management infrastructure.
  • Building skills in both employees and managers to make it all work.
Culture is the set of shared assumptions, beliefs and principles that a group holds. A certain set of beliefs and behaviors need to be developed to support engagement.

The most important people to exhibit these behaviors are front-line managers. They are in the best position to create a culture-and in the easiest position to destroy it-simply based on the frequency and consistency of engagement.

The beliefs that support engagement are centered around two fundamental principles. First, is the belief that everyone can make a contribution and is an expert at something. Second, is the belief that, given the opportunity, most people want to make a valuable contribution.

It’s important for front-line managers, and their supervisors, to espouse those beliefs. But, it’s even more important that they practice those beliefs through the right behavior. Behaviors are what people experience and it’s what influences their own behaviors.

So, what behaviors best demonstrate these beliefs? How a person reacts when someone makes a mistake is a great indicator. If the first reaction to a mistake is condemnation and chastising, then this is not consistent with a belief that people are intending to do good. On the other hand, if a mistake is met with empathy and support to correct the mistake, that is a very different experience for the individual.

The second element is building systems and processes that enable engagement. When conducting an assessment, one of the most revealing questions that I ask is, “If you have found waste or an opportunity to improve, what do you do with it?” I usually get answers ranging from “I don’t know” to “I wait for the next kaizen event.”

Without systems, we depend on the sheer willpower of the individual to decide to overcome momentum and make a change. This is a big chance to take.

When developing systems, lean managers should consider two important criteria in the design. First, consider the natural flow of work. You want people to be able to leverage what ever systems you design while they are doing the work.

Second, consider how you can enable decision making at the point of activity within the systems. This might be decision guides, criteria, standard work or simple empowerment. Anything that requires permission or interruption to complete a task is disempowering and disengages employees.

The third element of engagement is to be aware that skill gaps exist in both employees and managers. Most transformation efforts wrongly focus on only one group or the other.

Employees need to be able to identify problems. Have you ever asked a team, “What problems do you have?” and received the answer, “No problems”? Yet, problems seem to appear all over the place. We need to be able to consistently spot problems and opportunities.

In the future, I believe engagement will be one of the top performance differentiators. Are you doing enough?
 
 
Jamie Flinchbaugh is a founder and partner of the Lean Learning Center in Novi, MI, and the co-author of The Hitchhiker’s Guide to Lean: Lessons from the Road. He is a coach and consultant to executives and practitioners in industries ranging from hospitals to high technology. You can follow his writings on his blog at www.jamieflinchbaugh.com. To contact Jamie directly, go to the web site www.leanlearningcenter.com.

Share This Story

Jamie Flinchbaugh is a founder and partner of the Lean Learning Center in Novi, MI, and the co-author of The Hitchhiker’s Guide to Lean: Lessons from the Road. He is a coach and consultant to executives and practitioners in industries ranging from hospitals to high technology. You can follow his writings on his blog at www.jamieflinchbaugh.com. To contact Jamie directly, go to the web site www.leanlearningcenter.com.

Blog Topics

Austin Weber

Assembly Automation

Ergo Corner

Hoffmann on Testing

Jim Camillo

Jim Smith

John Sprovieri

Recent Comments

Helpful for Trainees

Cable Assembly Manufacturers

Huawei for manufacturing?

should have a scanner and then 3D print the repair

IPC-A-610 and IPC-j-std-001

Manage My Account
  • eMagazine Subscription
  • Assembly Newsletters
  • Online Registration
  • Subscription Customer Service
  • Manage My Preferences

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the ASSEMBLY audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of ASSEMBLY or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • ultrasonic welding
    Sponsored bySonobond Ultrasonics

    Engineering Efficiency in High-Performance Assembly: How Ultrasonic Welding Enhances Throughput, Reliability and Quality

  • UV curing system
    Sponsored byDymax

    Why UV Intensity Alone Doesn’t Define Curing Performance

  • wooden pallets
    Sponsored byLEAN Manufacturing Products

    Eliminating Waste on the Shop Floor: Applying Lean Principles to Improve Manufacturing Efficiency

Popular Stories

ASSEMBLY News Now, episode-30: Volvo Redesigns EV Manufacturing

Volvo Redesigns EV Manufacturing

Boeing CEO Kelly Ortberg announces 1 billion investment

Boeing Plans $1 Billion Wichita Investment, Workforce Training Center

GE Appliances Worker on Line

GE Appliances Expands Factory AI With 800 Gemini Enterprise Agents

Watch the latest episode of ANN now!

Events

July 24, 2025

From Shop Floor to CFO: How Manufacturers Are Closing the Loop Between Operations and Finance

On Demand Learn how manufacturers are bridging the gap between the shop floor and ERP systems to gain real-time visibility, streamline operations, and kick-start digital transformation—without waiting years.

Sponsored by:

PicoStratusGreen
July 30, 2025

Buffer Analysis and Design Fundamentals for Manufacturing Excellence

On Demand In this presentation, Dr. Herman Tang shares practical insights from his industry experience and research on buffer management in manufacturing operations.

View All Submit An Event

Poll

Difficult Assembly Processes

Which assembly process gives you the most difficulty?
View Results Poll Archive

Products

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

See More Products
Register for webinar - Modernizing Automotive Assembly: Why Upgrading Legacy MES is a Business Imperative
×

Never miss the latest news and trends driving the manufacturing industry

Stay in the know on the latest assembly trends.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Manufacturing Division
    • Store
    • Want More?
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • Newsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2026. All Rights Reserved BNP Media, Inc. and BNP Media II, LLC.

Design, CMS, Hosting & Web Development :: ePublishing