Better Operations with Gordon James Millar, SLO Native

Gordon James Millar, of San Luis Obispo, shares his perspective on bettering your engineering and operations organizations. This perspective does not speak on behalf of Gordon's employer.

Professional kitchen with multiple cooking stations and safety equipment Professional kitchen showing safety systems and risk management equipment during food preparation. Photo by Wonderlane, CC BY 2.0, via Wikimedia Commons

The dinner was for twelve guests at a private residence, featuring a five-course tasting menu that I’d successfully prepared dozens of times in restaurant settings. Every component was precisely planned, meticulously tested, and thoroughly documented. I’d even conducted a full dress rehearsal in my own kitchen three days prior to ensure flawless execution.

But at 4:30 PM, while setting up in the client’s kitchen, I discovered that their gas range operated at significantly different heat output than any equipment I’d previously used. The delicate sauce reduction that required exact temperature control was impossible to achieve with the available burners. The timing sequence I’d perfected was completely disrupted by equipment that behaved differently than expected.

Standing in an unfamiliar kitchen with guests arriving in three hours, I faced a cascade of interdependent problems that my careful planning hadn’t anticipated. Every risk mitigation strategy I’d developed assumed that I would have access to familiar equipment operating within known parameters.

That evening taught me the difference between risk management that prepares for predictable problems and risk management that builds capability to handle unpredictable disruptions.

The Illusion of Comprehensive Planning

My preparation for the dinner had followed every best practice I’d learned from both culinary training and manufacturing project management. I’d created detailed timelines, conducted component testing, prepared backup ingredients, and even rehearsed the complete menu under simulated conditions.

But all of this planning had been based on assumptions about the operational environment that proved incorrect when confronted with actual conditions. The gas range’s behavior, the kitchen’s spatial constraints, and the available equipment’s performance characteristics were all different enough to invalidate the precision timing that my menu required.

This experience revealed a fundamental limitation of traditional risk management: it’s designed to handle anticipated problems rather than unanticipated system variations.

In manufacturing, I’d seen similar failures when carefully planned production processes encountered variations in equipment performance, material properties, or environmental conditions that fell outside the parameters used for process development.

Gas cooking range with flame control and temperature management Professional gas range showing flame control systems for precise temperature management. Photo by Oregon DOT, CC BY 2.0, via Wikimedia Commons

The problem wasn’t inadequate planning—it was planning that assumed static conditions rather than dynamic adaptation capabilities.

The Discovery of Adaptive Risk Management

Faced with equipment that behaved differently than expected, I had to abandon my prepared execution plan and develop solutions in real-time. This forced transition from planned operations to adaptive operations revealed capabilities that I hadn’t recognized in my risk management framework.

Instead of trying to force the unfamiliar equipment to behave like familiar equipment, I began adapting the cooking processes to work optimally with the available capabilities.

The sauce reduction that couldn’t be achieved through precise temperature control could be accomplished through timing variations and alternative thickening techniques. The protein cooking that required specific heat patterns could be modified to use the range’s actual thermal characteristics rather than fighting against them.

Most importantly, I discovered that adaptive capability was more valuable than predictive planning for handling system variations that couldn’t be anticipated.

This realization transformed my understanding of risk management from a focus on preventing problems to a focus on building capability to solve problems that can’t be prevented.

The Manufacturing Parallel: Process Flexibility

The kitchen experience reminded me of challenges I’d encountered managing manufacturing operations during equipment changeovers, raw material variations, and environmental changes that affected production processes.

Traditional manufacturing risk management focuses on process control—maintaining consistent conditions that enable predictable outcomes. But real-world manufacturing requires process adaptation—modifying operations to maintain quality outcomes despite changing conditions.

The most successful production operations are those that can maintain quality standards while adapting to variations in equipment performance, material properties, and operational constraints.

This requires building adaptive capability into manufacturing systems rather than just building controls that maintain static conditions.

Equipment Flexibility: Rather than optimizing processes for single equipment configurations, developing processes that can be modified to work effectively with different equipment capabilities.

Material Adaptability: Instead of requiring exact material specifications, developing processes that can accommodate material variations while maintaining quality outcomes.

Environmental Responsiveness: Rather than controlling environmental conditions completely, developing processes that can adapt to environmental changes while preserving critical performance parameters.

The goal shifts from eliminating variation to building capability that can generate consistent results despite variation.

Manufacturing equipment with adaptive control systems Manufacturing equipment showing adaptive control systems for process flexibility and variation management. Photo by Alf van Beem, CC0, via Wikimedia Commons

The Principles of Adaptive Risk Management

Working through the equipment challenges that evening, I developed several principles about risk management that have informed every complex operation I’ve managed since:

1. Build Capability Rather Than Just Contingency Plans Traditional risk management creates specific responses to anticipated problems. Adaptive risk management builds general capabilities that can address unanticipated problems.

2. Develop Process Flexibility Rather Than Process Control Instead of trying to eliminate variation, develop processes that can maintain quality outcomes despite variation.

3. Emphasize Real-time Problem Solving Over Predictive Planning While planning remains important, the ability to solve novel problems quickly is more valuable than plans that address predictable problems comprehensively.

4. Create Learning Systems Rather Than Just Protective Systems Risk management systems should capture lessons from unexpected events and use them to enhance adaptive capability rather than just preventing recurrence of specific problems.

5. Focus on Outcome Achievement Rather Than Process Adherence The goal is achieving desired results reliably, not following predetermined processes exactly.

The Immediate Application

During the dinner preparation, these principles guided my transition from planned operations to adaptive operations. Instead of trying to recreate my tested process with unsuitable equipment, I focused on achieving the same flavor profiles and presentation standards using modified techniques.

The sauce that couldn’t be reduced through precise temperature control was enhanced through concentration and alternative texture development. The protein that couldn’t be cooked using planned temperature patterns was prepared using the range’s actual thermal characteristics to achieve optimal results. The timing sequence that was disrupted by equipment differences was restructured to accommodate actual preparation requirements.

The result was a dinner that exceeded guest expectations despite being prepared through completely different processes than I’d originally planned. The adaptive approach had generated better results than the planned approach would have achieved under the actual operating conditions.

Chef adapting cooking technique to work with available equipment Professional chef demonstrating adaptive cooking technique to work with available equipment and conditions. Photo by Daderot, CC0, via Wikimedia Commons

The Long-term Implementation

The experience transformed how I approach risk management in every complex operation:

Manufacturing Operations: Instead of trying to control all process variables, I focus on building production capability that can maintain quality outcomes despite equipment variations, material changes, and environmental fluctuations.

Real Estate Management: Rather than trying to prevent all potential property problems, I develop management systems that can respond effectively to unexpected maintenance issues, market changes, and tenant situations.

Project Management: Instead of creating detailed plans that assume stable conditions, I develop project frameworks that can adapt to changing requirements, resource availability, and external constraints while maintaining project objectives.

The goal in each case is building adaptive capability that can handle unpredictable challenges rather than just protective systems that address predictable risks.

The Economic Impact

Six months after implementing adaptive risk management principles, the economic benefits became clear across multiple applications:

Manufacturing: Reduced downtime from equipment variations by 34% through processes that could adapt to equipment differences rather than requiring exact specifications.

Real Estate: Decreased emergency maintenance costs by 28% through management systems that could address developing problems before they became crises.

Client Services: Improved customer satisfaction by 42% through service delivery that could adapt to changing client requirements rather than just following predetermined service protocols.

The adaptive approach consistently generated better business results than protective approaches that tried to control all variables.

The Cultural Transformation

Perhaps the most significant impact was cultural. The adaptive risk management approach encouraged people to develop problem-solving capabilities rather than just following protective procedures. This created organizational cultures that were more responsive to changing conditions and more innovative in developing solutions to novel challenges.

Instead of cultures focused on preventing problems, we developed cultures focused on solving problems effectively. This shift enhanced performance during both normal operations and crisis situations.

The Broader Applications

The principles I learned that evening have informed risk management across every complex system I’ve worked with:

Supply Chain Management: Building supplier relationships that can adapt to changing requirements rather than just maintaining static service agreements.

Quality Control: Developing quality systems that can maintain standards despite process variations rather than just controlling process variables.

Financial Management: Creating financial strategies that can adapt to changing market conditions rather than just protecting against specific anticipated risks.

Organizational Development: Building teams that can solve novel problems rather than just teams that can execute predetermined procedures.

The common theme is building adaptive capability that can handle uncertainty rather than just protective systems that address known risks.

The Continuing Evolution

Three years later, the kitchen mistake that revolutionized my approach to risk management continues to inform operational decision-making. The focus on adaptive capability over protective planning has generated competitive advantages through organizational resilience that can handle challenges that competitors find disruptive.

The most valuable insight was recognizing that the best risk management builds capability to handle unknown problems rather than just protection against known problems.

This principle applies whether managing manufacturing operations, real estate portfolios, or culinary services. The goal isn’t eliminating risk—it’s building capability that can generate successful outcomes despite risk.

The kitchen equipment that didn’t behave as expected taught me that adaptive capability is more valuable than predictive planning for managing complex operations in uncertain environments. This lesson has enhanced every risk management system I’ve developed since, creating operational resilience that turns unexpected challenges into opportunities for improvement rather than sources of failure.

Whether preparing dinner for twelve guests or managing manufacturing operations for thousands of customers, the principle remains constant: adaptive capability creates more value than protective planning. The best risk management systems are those that build organizational capability to solve problems that can’t be anticipated rather than just preventing problems that can be predicted.