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XLG SWISS
Lucyna Gorges speaking with two production workers beside a manufacturing line

change management

Change Management Consulting: Change That Sticks in the Plant

Change management is what happens between the decision and the change actually being lived. A new line, a new system, a new structure: the technical implementation can be planned, the human side cannot. I guide manufacturing companies through change processes, with change communication that reaches everyone from the machine operator to senior management, and with the experience of 13 years in the plant.

Sound familiar?

Change projects rarely fail on the substance.

01

The change has been decided, but the workforce heard about it in the canteen. The rumours are faster than the communication.

02

Employees see the change as a threat. What follows is working to rule and, in the worst case, resignations from your top performers.

03

Middle management is supposed to carry the change but was never convinced itself. Foremen and team leaders nod upstairs and put on the brakes downstairs.

04

It is the third change project in four years. The workforce has learned that waiting works: it will pass.

05

The project is technically finished, but nobody works with the new process. After three months everything is back to the way it was.

What change management means in practice

Change management is the structured guidance of a change process from analysis through to embedding. The models are well known: Kotter's eight steps, the ADKAR model with its five phases Awareness, Desire, Knowledge, Ability and Reinforcement, Lewin's three-phase model. They are all useful as a map. None of them replaces the work on site.

That work consists of a few things that have to be done consistently. First, understand who the change affects and how: the stakeholder analysis. Second, explain why the change is necessary, in a change story that is understood on the shop floor too. Third, enable the managers, because they carry the change, not the change manager. Fourth, take resistance seriously instead of ignoring it. Fifth, keep following up on the change until it has become routine.

My change consulting combines this with Lean. Most changes in plants are process changes, and I know both sides: the method being introduced and the people who are expected to live it.

Large mechanical engineering assembly hall with overhead crane and several production lines
High-output food production line with stainless steel equipment and hygiene clothing

How I work

A change process with me has five phases, based on the well-known models but translated for plants:

  • Analysis

    What changes for whom? Stakeholder analysis across all levels, conversations with those affected, assessment of support and resistance. Honest, not sugar-coated.

  • Change story and communication concept

    Why now, why this way, what does it mean for you? A story that senior management, the foreman and the machine operator can all tell in the same way. Plus a communication plan: who says what, when, through which channel? Town hall, team meeting, board, notice board, one-to-one conversation.

  • Enabling the managers

    Briefings and training for all management levels before communication goes down the line. The manager has to be able to answer the questions that will come.

  • Supporting implementation

    Regular mood checks, dealing with resistance, adjusting communication, making quick wins visible. In this phase I'm in the plant.

  • Embedding

    New routines, standards, key figures and regular communication routines until the new state is the normal one. Success monitoring with key figures, not with gut feeling.

What you get

A change that reaches the people and holds after the project:

  • Stakeholder analysis with an assessment of influence, degree of impact and attitude for each group.

  • Change story in versions for senior management, managers and employees.

  • Communication concept with channels, timeline, responsibilities and key messages.

  • Managers who are trained to explain the change and to work through resistance.

  • Action plan with quick wins, milestones and success indicators.

  • Support through the critical phases on site and embedding in routines and standards.

Intro call

Book your call now: 45 minutes, no obligation.

You describe your starting point, I tell you openly whether and how I can help.

Lucyna Gorges, lean and change consultant, XLG SWISS

Frequently asked questions

Change management: questions from practice

What is change management?

Change management is the planned guidance of a change process in an organisation, from analysis through communication to embedding. It takes care of the human side of change: do those affected understand why something is changing, are they willing to go along, can they do the new thing, and is it being followed up? The tools are stakeholder analysis, change story, communication concept, enabling managers and success monitoring. Without change management, a change often ends up technically finished but practically unused.

What phases does a change management process have?

Most models describe a similar sequence. It starts with analysis (what changes, for whom, with what consequences), then preparation with change story, communication concept and enabling of the managers. Then comes implementation, in which you communicate, train and work with resistance, and finally embedding, in which the new becomes routine and relapses are prevented. Lewin sums this up as unfreeze, change, refreeze, Kotter in eight steps, ADKAR in five. In practice the phases overlap, and embedding is the one most often neglected.

Which change management models are there, such as ADKAR and Kotter?

The ADKAR model describes five steps that every single person has to go through: Awareness (of the need), Desire (the will to take part), Knowledge (of how), Ability (to actually do it) and Reinforcement (so that it sticks). It is well suited to diagnosing where a person or group is stuck. Kotter's eight steps describe the process at the organisational level: create urgency, build a guiding coalition, develop a vision, communicate it, remove obstacles, create quick wins, build on successes, anchor the change. Add to that Lewin's three-phase model and the Kübler-Ross curve for emotional reactions. I use them as maps, not as recipes.

What does a change manager do?

A change manager plans and supports the human side of a change. They analyse who is affected and how, develop the change story and the communication concept, prepare managers for their role, facilitate workshops, hold conversations with those affected and measure whether the change is landing. They are not the one who pushes the change through; that remains the job of line management. A good change manager makes the managers capable of acting instead of doing the work for them, and is present where the resistance is.

Why do change projects fail?

In my experience, at five points. First, the urgency is not explained and the workforce does not understand why; second, middle management is bypassed and does not carry the change. Third, communication happens once, as an announcement, and then never again; fourth, resistance is treated as a disruption instead of as information. Fifth, the project ends with the technical implementation, and nobody follows up until the new way has become a habit. Anyone who takes these five points seriously has done the largest part of change management.

How do I deal with resistance to change?

Resistance is normal and usually justified; it shows that people are taking the change seriously. The first step is to listen: what exactly does the person fear, what are they losing, what do they not know? Often there is factual information behind the resistance that the project needs. The second step is to answer honestly, even when the answer is uncomfortable. The third is to turn those affected into participants: whoever helps build the solution does not fight it. What does not work is ignoring it or applying pressure; both turn open resistance into silent resistance, and that is more dangerous.

How do I communicate change in the company properly?

Early, honestly, repeatedly and through the managers. Early means: before the rumours get there first. Honestly means: also saying what is still unclear instead of pretending certainty. Repeatedly means: one announcement is not enough; the message has to come back over weeks in town halls, team meetings, at the board and in one-to-one conversations. Through the managers means: the direct supervisor is the most important source of information, so they have to be informed and enabled before everyone else. And every communication answers the question every affected person asks: what does this mean for me?

What is a change story?

The change story is the coherent narrative of why a change is necessary, where it leads and what it means for those involved. It answers four questions: where do we stand, why can we not stay as we are, where are we going, and how do we get there? A good change story is short, concrete and in the language of the listeners; the version for the shop floor sounds different from the one for the board of directors but says the same thing. It is the basis for all communication in the project and ensures that senior management, foremen and machine operators tell the same story.

How does a change project with you work?

After the initial consultation, I clarify the assignment and scope with you: which change, what time frame, what role for me. Then comes the analysis phase with stakeholder conversations, usually two to three days on site. From this come the change story, communication concept and action plan, which I agree with you. Before communication starts, I train the managers. During implementation I'm in the plant at fixed intervals, facilitating, coaching and adjusting. The support ends when the change is embedded in routines, not when the project is technically finished.

Automated manufacturing cell with robots and a gantry loader in metal processing

Book consultation

45 minutes, no obligation. Tell me what change is coming up and who does not want it.