Welcome to the Lean Focus podcast where we bring you inspiring stories of lean transformation with your host Damon Baker.
Jason, FuelCell Energy has been a pioneer in clean energy for more than 50 years. The technology is powerful, the mission matters, and the opportunity is enormous. Yet, when you stepped back and looked at the business, you realized something deeper had to change. Can you take us back to that moment? What did you walk into and what told you that maintaining the status quo wasn't going to be enough anymore?
Damon, thank you. It's a great question. When I joined the company, we had a number of different critical challenges that we were facing — financial execution and productwise. We had so much to accomplish. We needed a better way to organize work so we wouldn't try to boil the ocean because then nothing gets done. We needed to execute faster. We needed to be more nimble. So, we needed to find a way to get that done.
I'm always curious. I hear the term maintaining the status quo. We kind of use it as a part of our language. It seems like when you were observing the team, what did maintaining the status quo physically look like day-to-day in terms of the execution?
It meant being less commercially focused. I mean, we were a company that had been around for over five decades. We were a research-minded organization. So, the definition of success was very different. The definition of success was solving problems even if those were only solving problems that we found interesting but weren't solving customer problems, and that needed to change. So continuing in the status quo was simply not an option if we were going to be successful.
And what was driving the need for speed and focus where that was really becoming non-negotiable at this point in time of the 50-year journey?
The clock was running financially. We had significant debt that we needed to satisfy. We had a lot of cost both in the operations of our business and we were spending money on R&D. We needed to move quickly because time, you know, it really felt like in our company the old saying is, you know, time costs money and that was very much the case for our company.
Where did you feel the gap was most glaring between the ambition that the company had to be great and to grow and the execution that they were actually delivering on?
I think it was two things. I think everybody's really passionate about the business. Everyone's really passionate about our technology. Everyone believes in the purpose that we have as a company, which is to enable a world powered by clean energy. And we believe we can do that. The question was how are we going to do it? So we needed tools. We needed a methodology. We needed a repeatable way to approach our work. We needed a way to know that we were being successful. We needed to know what the current status was, what we were trying to get to, what it was going to take to get there, and then measure along the way that we were actually progressing toward our north star. And that was what was going to be critical to us being able to be successful on our journey.
So it sounds like the burn rate of capital and the investment is really the wakeup call for the organization. Was that your observation, the board's observation, a collective observation?
I think it was the collective observation of the company. However, the one challenge for the company was that the company had faced financial challenges in the past and has always found a way through grit and determination to work its way out of it. So getting people to really believe that this time was going to be different was part of the leadership challenge, and I had to find ways to communicate that message and get buy-in throughout the organization. The board was clearly aligned. The senior leadership team was aligned. Now we had to get everyone in the same boat rowing in the same direction.
Yeah. To me, this is probably the most challenging aspect — the company had so much to accomplish in a short amount of time. Yet, when you looked around in the organization, people were seemingly overloaded and had lots of quote-unquote work to do, but the priorities themselves were very unclear and everything felt important to everybody all at once. So, take us back to that time. What did you see happening to teams that were suffering through that when priorities just weren't clear in terms of what they're working on?
Well, I think in the void of clear direction, people create what's important in their own mind because no one wants to come to work — or at least most people don't want to come to work — and feel like they're not accomplishing anything. So, they make the task that they've decided to work on become the really important task. And unless you can really make clear for people what exactly is required, what exactly is needed, what exactly are the priorities for the business, then people do what they think are the right things to do. And it's incumbent on leaders to make it clear to people what their priorities are and how their role plays into the broader success opportunity for the company. So for us, what we tried to do was develop a methodology or utilize a methodology to do that. We initially started doing that with OKRs, and the goal around using OKRs was to really break the work into small chunks — daily, weekly, monthly, quarterly — so people could really be clear about what they needed to do, track it on a daily basis, weekly basis, monthly basis, and then we built an operating system around that. Unfortunately, it never really became part of our total DNA. But for me, I know that the best operating companies have a clear way of working and they simplify work. They make tools and processes available for what people need to do to get their work done, and we needed to find the same way of working at our company.
Yeah. You mentioned OKRs and it sounds like that was a new alignment strategy in terms of driving the right clarity and performance and metrics and things like that, but you said it was a struggle. What was the organization fighting against? So what were they trying to retain in lieu of OKRs? What were they trying to still do that made OKRs maybe not part of your DNA?
You know, it was an interesting dynamic because inside our organization — and I think this is true in most organizations — people say we have too many priorities.
So with OKRs, you know, you start by trying to really make the priorities clear — four priorities, five priorities, six corporate priorities — and then you try to cascade those priorities throughout the organization. And then what you realize is that five priorities or six priorities become hundreds of priorities as you cascade them throughout the organization. And you find yourself right back at the point where people are saying we have way too many priorities. And it became really hard to distinguish between things that just need to get done inside of a company — we need to offer an insurance plan, we need to pay people. Those are important, but those are not our priorities for the business. And people begin to cascade these things throughout the OKRs and they become rather lengthy. And then the process to try to really simplify that to manage them on a daily basis, a weekly basis, a monthly basis, a quarterly basis becomes very complex, takes a lot of time and energy. And you're spending more time managing and reading out on OKRs in many cases than you are in doing the work. And so we knew we needed to do something different as a company in order to drive transformation because what we needed people to be able to do is do two things at the same time. We needed them to perform against the set of priorities while we were also trying to transform this company, and that's what we were trying to get done.
Yeah. The distinction between daily management — keeping the trains running on time and executing all the business-critical things like you'd mentioned, payroll and benefits and those kinds of things. But then there's breakthroughs that have to happen and we have to make capacity and room for those things to execute those things and resource them accordingly. Otherwise, people become all about the daily management and we look several years down the road, we get passed up because we're not innovating, we're not improving. Did you see any of that? Did that resonate with you?
Absolutely. I think, you know, as a company whose roots, whose DNA is innovation — and that's one thing that we've always been, is an innovation company — but there is a transition that we needed to go through that wasn't just innovation for innovation's sake, as people sometimes say, but it was innovation for customers, solving customer problems. I like to say, you know, innovate, need to sell. That's what we were there to do. And so that meant you needed to really understand customer problems and opportunities, and then how the application of our technology would address those customer problems and opportunities and do that better than the competition or alternative choices that a customer may have. And so in that mindset of innovation and in the belief that what we do is very complicated, one of the transitions we had to drive or beliefs was that speed and quality can coexist, and we needed to do both in order to win in the marketplace. And that required changing the mindset of some incredibly talented, innovative scientists and engineers across our organization.
Yeah, you asked the question, how do we fundamentally change the way we work? And you just gave two great examples. One is let's stop innovating for ourselves and convincing ourselves that this is a cool new thing — check this out — versus customer-back. Let's solve problems that the innovation is the answer for. That's a big change in way of working. And then the other one you mentioned is really what I call the power of 'and.' A lot of organizations make false trade-offs, false dichotomies, and you just — speed and quality is one. It's like you can have it fast, but you can't have it right. You can have it right, but you can't have it on time. You've seen the poster, I'm sure.
What other things did you observe that the organization really had to change their thinking about in order to get better and then ultimately how they worked?
I think other things that we had to change was, you know, when you think about an organization who's rooted in innovation and we do something that is fairly unique and differentiated — we take fuels and we don't combust them, we reform them, and we make electricity, and we do that cleaner and more efficiently than traditional technologies, and that's an incredible innovation and it's chemistry at its best. But when you think about that, one of the other things that needed to change was that we didn't need to be the company that did everything on our own. There were certain things that we could go outside to other companies who wake up every day trying to solve a specific problem that we're trying to sometimes solve that they do all the time and they do it better than us. And we could integrate those things into our technology. So getting people to accept that we can look for integration of other technologies and engineering solutions as we integrate into complex solutions for customers was another way that we needed to change in the way we work as a company. And then from a management team perspective and how we allocated capital, we needed to have more of a mindset that you had to earn the right to spend the capital, which meant you had to have clear milestones and markers. You had to hit those milestones and markers in order to get that next tranche of capital. Almost similar to a VC model, if you will. You get your A round of funding and you've got certain targets you need to hit and you need to hit those and show that it actually accomplishes what you projected, and then there's a B round of funding. And that really changes the mindset and pace at which work gets done.
You made a decision early on — and we're going to talk a little bit about the history of that — that you were going to embark on a lean journey. Often times when CEOs and leaders such as yourself announce that to the organization, there's a collective gasp and a sigh of relief. It's like, oh, here we go again, or lean is going to be one more thing. It's going to be a flavor of the month program and those kinds of things. So, you didn't hesitate though at this point. You were very clear-eyed that lean was hard and you did some research on that which we're going to get into. But one of the things that you observed is that the organization need to slow down, ask better questions, and changing their behavior was really far tougher than chasing the next shiny idea. So it wasn't a lack of ideas, it was really changing the way we thought, the way we led. So kind of given the nature of how OKRs went, which we talked about earlier, what concerns did you have about lean being seen as one more flavor of the month and maybe even a contradiction or as a replacement to OKRs and then creating more confusion in the organization?
Damon, I'll tell you, when I sat down with the executive leadership team and I had made the decision that I was going to tell them that we were going to embark on a lean system and we were going to build the FuelCell Business System. I joked a little bit about it being called FBS because everyone knows I'm a big college football fan. So, I'm like, we're going to be in the FBS. And I knew it would be a bit of a challenge because I'm the one that also introduced OKRs. And so I felt as though the risk was that the team was going to have 'here we go again, flavor of the month.' But I did a lot of work upfront in reading and trying to understand and making sure that I could really articulate my why as to the reason we were going to move to lean and have lean be the foundation for our business operating system. And I knew it would be harder because we'd already tried OKRs. We wanted to make sure that lean wasn't perceived as the flavor of the month. And creating the lean business system became really the focal point to say we need a repeatable way to work. We need to make our work visible. We need to make sure that everybody understands what they need to do, what they need to do every day when they come to work. And we need to give them the tools and the methodologies to do that. But we also need to give them the tools and the processes that if they think we can do things better, that we have the ways in which we can receive that information, we can validate those changes, and then implement those changes as opposed to people just deciding to do work the way they wanted to do it. And I think that really resonated with the leadership team and I made it very clear that I too was going to operate from a lean perspective and the way in which I was going to engage with each of the leaders was going to be around lean and when we met in our one-on-ones we were going to talk about A3s and we were going to talk about bowlers and we were going to go through all these things to really change the way in which we ran our business. We then probably made our smartest move in our lean journey. And I'm not just saying this just because I'm talking to you. We hired you guys to help us figure it out. And you were incredible.
Thank you so much. In your view, and you've been at this a little while now, you mentioned tools, you mentioned business system, and there's a big difference, as I'm sure you know. So looking back on this, why is it so difficult to build a business system versus just using the tools that we all heard and know? You mentioned a few like KPI Bowlers and A3s and things like that because I think part of it is...
You have to do the work to ensure understanding. You have to get to a common language. And in order for people to attack a problem, to work their way through a problem, to get to a root cause on a problem, the communication between those team members needs to be clear. So when one team member says X, every other team member needs to understand what X means. And so getting to that clarity and doing the work to do the training and the education is really important. And I have a board member who recently just retired from GE Aviation or Aerospace now. And she led the lean work at GE Aerospace. And to hear her talk about the common language across the organization, the amount of training they go through up through and including the CEO, I knew it would be a challenge, but I knew the reward would be well worth it. And as we started to do this, because we weren't in a position to roll out lean across the entire organization at once, so what we tried to really do is pick some high-profile things that we could go attack, show success with lean, and get that buy-in, and get people to start saying, 'I want to be a part of that.' And that's the way we approached it.
So, at this point, you're starting to find some guides. You mentioned one, but you were able to see what good looks like outside of FuelCell Energy. And one of the turning points is actually seeing a clear way of what you were trying to achieve with the business system actually working somewhere else with far greater complexity that had all the same similar challenges to you that went through a very similar transformation in a very short amount of time. So you're not just hearing the lip service of people talking about it — you're actually observing it in action with leaders who 18 months prior to your arrival probably didn't even know, many of them, what lean was and here they are leading it out front. So you visited GE Aerospace and what struck you most about that visit with GE Aerospace when you saw that shared language, to use your words, in action?