The Hidden Factory

Book by Doc McIntyre,

We say, “Don’t judge a book by its cover,” but the reality is we’re wired to scan and interpret our environments.

So my coaching is…

Go ahead and judge the cover… and then open the book and read the story.

Don’t stop at the cover.

How Many Workarounds Are in Your Business? - The Hidden Factory

Let's talk about the "Hidden Factory." You know what I'm talking about—the unofficial, undocumented processes that pop up when things don't go as planned. These workarounds become part of the daily grind, often without anyone really noticing. But let me tell you, they’re killing your productivity, eroding your profits, and making your life harder than it needs to be.

The Hidden Factory exists in every business. It's where employees create their own ways to get the job done when the official process doesn't cut it. Maybe it's that extra step in the production line because the equipment isn’t reliable, or maybe it's the workaround your team developed because the software you invested in is a nightmare to use. These workarounds are usually born out of necessity, but over time, they become ingrained in the culture. They’re accepted as “just the way we do things around here.”

Here's the thing: every workaround is a red flag. It's a sign that something in your system is broken, inefficient, or just plain wrong. If you're not actively rooting out these hidden processes, you're letting inefficiency rule your operation. You're giving up control over how work gets done, and that’s a dangerous place to be.

In Lean Manufacturing, we strive for simplicity, efficiency, and consistency. Workarounds are the enemy of all three. They introduce variability, increase the chance of errors, and make it impossible to scale or sustain improvements. If you want to build a kick-ass culture, you need to shine a light on these hidden factories and eliminate them for good.

Start by asking your team where they’ve created their own processes. Don’t approach this like an inquisition—make it clear that you’re looking to make their jobs easier, not point fingers. When you identify a workaround, dig deep to understand why it exists. Is the official process flawed? Is the equipment unreliable? Is the training inadequate? Whatever the reason, fix the root cause, not just the symptom.

Once you’ve rooted out these inefficiencies, standardize the improved process. Make sure everyone knows the new way is the only way. Train your team, document the process, and keep an eye out for new workarounds cropping up. Remember, continuous improvement isn’t a one-time project; it’s an ongoing commitment.

The Hidden Factory is one of the biggest obstacles standing between you and operational excellence. By identifying and eliminating these workarounds, you’re not just fixing problems—you’re taking control of your business. You’re setting the stage for a culture of efficiency, consistency, and long-term success.

Go and Get Sh!t done!

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