At its core, Lean is about people–respecting them, empowering them, and ensuring their well-being while driving continuous improvement. Recently, GE Aerospace's Lynn, MA, facility provided an inspiring example of what it means to put these principles into action, even under challenging circumstances.
Read more about this and/or watch a video at this link:
Keep the Line Moving: GE Aerospace's Lynn Facility Is Using FLIGHT DECK to Put Safety First
Imagine being at a busy jet engine production facility on the last day of the quarter. Orders must ship, commitments must be met, and pressure is high. Suddenly, a key overhead crane–a critical piece of equipment used daily–needs to be shut down immediately for safety reasons. For some organizations, the temptation to prioritize production over safety might have been too great, sadly.
But not at GE Aerospace Lynn.
Safety First, Always
When the issue with the crane arose, site leader John McCarron and his team made the bold and correct decision: shut it down.
As Matt Allen, the EHS leader, explained, the decision was guided by safety protocols and the recommendations of the equipment manufacturer. This meant halting operations involving the crane despite the potential impact on production.
This safety-first mindset echoes the philosophy of the late Paul O'Neill, former CEO of Alcoa. O'Neill famously said that worker safety is a moral imperative and the foundation for operational excellence. By putting safety first, GE Aerospace demonstrated a deep respect for its team members and commitment to long-term success over short-term gains.
The Lean Response
What happened next at GE was a testament to the power of Lean thinking and committed, principled leadership (from CEO Larry Culp on down). The team quickly assessed their options, collaborating across roles to identify a solution. Within just ten minutes, they had shifted operations to an alternate crane, ensuring that production could continue safely and without delay.
This response exemplifies the principles of Kaizen (continuous improvement) and problem-solving central to Lean. Rather than compromising on values or safety, the team worked together to address the issue creatively and effectively.
Results That Matter
Not only did the Lynn team manage to ship all scheduled engines on time, but they also reinforced a culture of trust and empowerment. Their quick decision-making and commitment to safety reflect the deeper benefits of Lean: fostering an environment where people feel respected, supported, and confident that doing the right thing is always the right choice.
Since adopting Lean principles through their FLIGHT DECK operating model, the Lynn facility has achieved remarkable improvements, including a 55% reduction in illness and injury rates since 2022. It's a testament to how prioritizing safety and continuous improvement can lead to both better people outcomes and operational success.
Reflecting on Lean Leadership
This story serves as a powerful reminder for all of us. True Lean leadership isn't about cutting corners to hit numbers–it's about respecting people, maintaining integrity, and solving problems together.
So, let me ask you:
What's a time when you or your team prioritized safety or core values over short-term results? How did it impact your organization in the long run?
I'd love to hear your stories in the comments below!
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