During a period of low team morale due to missed production targets, I introduced a real-time performance dashboard that visualised key metrics such as output rate, defect levels, & downtime. Each team member had access to this dashboard, & it allowed for instant feedback on their performance. In my experience, when employees can see real-time data & how their specific role impacts overall performance, it increases accountability. For example, when we implemented this during a project, we saw a 10% improvement in output in just one month, as operators could immediately adjust their work based on the data. This immediate feedback loop was key to keeping the team motivated.

Production setbacks are a part of operations, with each day presenting new challenges, whether related to breakdowns, manpower, quality concerns, material availability etc. To boost motivation during these times, the team should always stick to the basics; have proper communication, set realistic KPIs and goals, give consistent feedback, and also have balanced mix of short-term and long-term objectives. By focusing on the fundamental principles and actively involving the team in problem-solving, you can cultivate a resilient workforce that remains motivated, regardless of the challenges they encounter.

In my experience as a manufacturing person for three decades, this situation is quite common. The strategy I used to take to set small day wise goals. Instead of adopting a "do it as I tell" approach, I always used "how can we make it happen" approach to all stakeholders. Another important intervention was to stand with the team at the gemba for hours together to solve the problems together. This gives a moral boosting to the team members and drives them towards innovating approaches. Celebrating small successes at every stage can also be helpful.

Boost motivation by being honest about challenges, recognizing hard work, involving the team in finding solutions, offering training, and showing you care about their well-being and progress.