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Why Operational Excellence Fails in Manufacturing—and How to Make It

Manufacturing organizations rarely struggle because their people are unwilling to work hard.

In fact, one of the most revealing things I have observed throughout more than 30 years in manufacturing leadership is just how hard people will work to keep an unstable operation running.

Operators compensate for unreliable equipment.

Supervisors rearrange schedules around material shortages.

Maintenance technicians repeatedly repair the same failures.

Quality teams inspect defects out of the process.

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