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When Lean Isn’t Enough

A journey through bottlenecks, contradictions, and breakthroughs

Hoi An and Da Nang Photographer / Unsplash

Akhilesh Gulati
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PIVOT Management Consultants

Thu, 04/16/2026 - 12:03
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On an assembly line for household appliances, 10 operators assembled motors for downstream production. Demand was high, but output consistently fell short—and many motors failed final inspection, requiring weekend overtime to catch up.

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Managers tried the usual fixes. Push the operators, tweak the workstations, reduce wasted motion. For a day or two, it looked like progress. But by Friday, the numbers told the same story.

One afternoon, I asked the line boss, “Why do you think the line keeps falling behind?”

She shrugged. “Honestly? Some of the guys just... slow it down. Makes overtime worth it.”

The truth was unmistakable. Defective motors repaired on Saturdays at time-and-a-half pay often made up the week’s shortfall. The system rewarded defects. The constraint wasn’t the workers or the machines; it was a policy contradiction.

 …

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Comments

Submitted by Steve (not verified) on Thu, 04/16/2026 - 09:18

Lean, TOC, TRIZ

This sentence "Restructure pay and production expectations so that weekday output was rewarded, while overtime repairs no longer created a shortcut." seems unnecessarily vague. HOW did the pay and productions expectations change? Were the workers paid a piece rate? According to my training in lean, a piece rate is counter intuitive. If they were paid a piece rate how much was it and did it really make up the difference of 4 or 5 hours of overtime pay? 

Awaiting your response,

Steve

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Submitted by Akhilesh (not verified) on Fri, 04/17/2026 - 11:09

In reply to Lean, TOC, TRIZ by Steve (not verified)

Lean TOC & TRIZ: Restructure pay and production expectations?

That’s a helpful question, Steve.  Thank you for pushing for more clarity.

In the article, I compressed what was actually a broader shift in how performance and incentives were aligned. This was not a move to a traditional piece-rate system; as you noted, that approach can introduce its own issues in a lean environment.

The changes focused on removing the unintended incentive to shift output into overtime:

Weekday expectations were clarified at the team level, with visible daily targets so that completing work in regular hours became the norm. The advantage of weekend rework was reduced or eliminated, primarily by tying performance recognition (and where applicable, variable pay) to first-pass yield and weekday completion rather than total repaired volume.

In other words, the system began to reward right-first-time output during regular hours, instead of volume recovered later through overtime.

The exact compensation mechanics can vary by organization (as I'm sure you're aware), which is why I kept that portion at a higher level. The central point is that once the contradiction was removed - a system asking for throughput while rewarding delay and defects - the behaviors and results shifted quickly.

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