Tag Archives: how to keep projects on track

Common Pitfalls to Completing Improvement Projects


As I’m sure you are aware, to get and stay ahead of the competition, it is all about how to improve further and faster. But sometimes, despite the best intentions, our continuous improvement efforts can get bogged down.

While there can be a number of reasons for delays and the related under-achievement — such as failing to identify root causes — we have identified common pitfalls that every improvement leader should avoid.

Here’s a list of the top three along with some ideas on how you might avoid them:

  1. Pace: The most common cause of delay in achieving results is the pace. Some teams schedule an hour a week to work on the project, so that under the best of circumstances, two months will pass before the project gets one day’s attention. But far more often it will take three or four months to complete one day’s effort on the project because meetings get cancelled, or start late, and then a portion of each meeting is spent going over the status or covering old ground for a member who missed a meeting. And, of course, the current pandemic has complicated meeting schedules and effectiveness. Regardless of reason, when a project progresses this slowly, priorities may change or resources might be reassigned without ever completing the work and gaining the improvements.

    The secret to avoiding this trap is, to the fullest extent possible, employ the Kaizen approach. Kaizen requires planning and data gathering up front and then all the necessary people are pulled off their jobs for one day or several days to completely solve the problem: designing, testing, stabilizing solutions usually in under a week. The Kaizen approach requires good planning on the part of the leaders and facilitator, but makes good use of the entire team’s time while accelerating the benefits of the improvement effort.
  2. Scope: The second most common trap that slows down progress is a poorly designed project scope. The scope may start out too large — i.e., trying to take on all locations, departments, functions, product lines, etc. all at once. When the scope is too large, you have too many aspects of the problem to track down, analyze, and address, and too many people to consult, inform, an persuade. A team’s progress can also be inhibited if too much of the scope falls beyond their sphere of control. For example, if a receiving team wants to address a Purchasing process or a Manufacturing team wants to address an Order Entry process.

    Sometimes a project begins with the intention of being short and sweet, but gradually the scope keeps growing until the project is in danger of crumbling under its own weight.

    Avoid the scope-trap by explicitly raising and resolving as many questions about scope as possible. Define the scope so that improvement results can be realized as quickly as possible. Decide what locations, functions, departments are in scope by identifying the one or two that will provide the biggest impact (you can do this by stratifying the data you used to quantify the opportunity). Decide what types of problems are out of scope. You may decide that systems design issues should be out-of-scope if the organization already has a multi-year waiting list for systems changes. An area that is slated for major change in the near future often should be deemed out-of-scope. Be clear about the expected project deliverable. Sometimes improvements can be implemented, verified, stabilized. In other situations, the project team may be chartered to merely gather, analyze, and report data about the problem.
  3. Poor communication: Sometimes delays are caused by insufficient communication, especially today when many of us are working remotely. When a team leader does not communicate regularly with the sponsor, many delays can crop up: the team leader misses out on useful information that the sponsor has on the topic; a team struggles with obstacles that the sponsor can move out of the way; a team becomes set on a solution that the sponsor feels is untenable or does not understand well enough to give it full support. Many things can go awry when the team and the sponsor are out of touch.

    This pitfall is easy to avoid by discussing these risks up front with the sponsor and agreeing how frequently to communicate about the project. The frequency really depends on the speed of the projects. If you are executing a Kaizen, you should communicate in advance and update the sponsor at the end of every day. If your improvement team is meeting an hour a week, perhaps too little happens to merit a weekly update, but a team leader should not go more than three weeks without updating the sponsor. Agree on the update schedule and put it in your calendars for the expected duration of the project.