Rethinking the Org Chart: Why Successful Companies Avoid Overloading Managers

In today’s business climate, reorganizations have become the norm rather than the exception. Companies shift structure to respond to market changes, streamline costs, adopt new technologies, or realign with strategy. But while the headlines focus on job cuts or new leadership, one critical factor often overlooked in the success or failure of a reorganization is managerial span of control: the number of direct reports assigned to each manager.


When companies get this wrong, they risk derailing even the best-planned structural change. When they get it right, the results include faster decision-making, improved employee engagement, and better execution of strategic goals.

So how do the most successful companies handle this delicate balance during a reorg?


The Pitfalls of Overloading Managers


The pressure to do more with less can tempt organizations to increase the number of employees reporting directly to each manager. After all, fewer managers mean lower salary overhead, less bureaucracy, and theoretically, a leaner, faster organization.


But research consistently shows that increasing a manager’s span of control beyond a certain point leads to declining effectiveness, both for the manager and their team.


According to a comprehensive study by Bain & Company, companies with top-quartile performance in productivity and employee engagement tend to cap manager spans at no more than 7 to 10 direct reports, depending on the complexity of the work and the level of autonomy of the team.


Beyond this range, several problems begin to surface:

  • Decreased coaching and development time: With too many direct reports, managers struggle to provide regular feedback or support individual growth.
  • Slower decision-making: Managers become bottlenecks as more team members wait for approvals or guidance.
  • Increased burnout: Overloaded managers report higher levels of stress, disengagement, and turnover.
  • Reduced innovation: Less time for strategic thinking means less opportunity to solve problems creatively or improve team performance.


Harvard Business Review echoes this concern, noting that “as spans widen, the average quality of management and leadership drops,” especially in knowledge-driven or high-complexity work environments.


Span of Control: One Size Doesn’t Fit All


So what’s the right number? The answer depends on context, and smart companies know that not all roles, teams, or business units require the same structure.


Key variables include:

  • Task complexity: Teams doing routine, repeatable work (like call centers or transactional processing) can operate effectively with spans as wide as 15-20 direct reports. In contrast, research and development teams often require narrower spans due to higher collaboration and oversight needs.
  • Employee experience: Highly experienced, autonomous employees require less hands-on supervision, allowing for broader spans.
  • Manager capability: Not all managers are equally equipped to handle large teams. Leadership training, experience, and support systems (like team leads or AI tools) can influence optimal span.
  • Organizational culture: Companies with strong cultures of self-management and clear accountability structures may tolerate wider spans without performance drops.


A 2023 McKinsey report emphasizes this variability, stating, “Leading companies tailor spans of control by role and level, not by arbitrary benchmarks.”


Case in Point: Reorg Success Stories


Let’s look at a few organizations that have successfully navigated reorgs by paying close attention to managerial spans:


1.  Microsoft

During Satya Nadella’s early tenure as CEO, Microsoft underwent a major organizational overhaul to break down silos and improve collaboration. A key part of the strategy was flattening the org, but not indiscriminately. Nadella emphasized “clarity of purpose” and invested heavily in leadership development to ensure managers were ready to handle broader spans only where appropriate.

The result? Productivity rose, engagement improved, and innovation accelerated across product teams.


2. Procter & Gamble (P&G)

P&G restructured in the early 2010s to reduce costs and improve agility. Rather than simply cutting layers, the company also reassessed manager-to-employee ratios by function. In areas like finance, where standard processes prevail, spans increased. In innovation and marketing roles, they were kept tight to preserve creativity and oversight. The tailored approach helped P&G maintain performance through a major shift.


3. Spotify

Famous for its “squad” model, Spotify empowers small autonomous teams with clear leadership support. Managers, often called Chapter Leads, have limited spans to ensure close mentorship and skill development within specific technical domains. This model has supported Spotify’s growth while preserving agility and innovation.


Practical Guidance for Leaders Planning a Reorg


If your company is considering, or currently navigating, a reorganization, here are five evidence-based principles to keep in mind:


1. Start with the work, not the structure

Begin by analyzing the actual tasks teams are responsible for. How complex is the work? How interdependent are the roles? What level of oversight is needed? Design the structure around the needs of the work, not arbitrary span targets.


2. Avoid flattening without a function

Flattening layers can reduce costs, but it can also create chaos if not executed thoughtfully. Ensure that wider spans are matched with the right capabilities, tools, and cultural support.


3. Invest in manager readiness

If you do decide to widen spans, ensure your managers are trained in time management, delegation, coaching, and the use of technology. Even experienced managers can falter without support.


4. Use data to monitor and adjust

Keep track of KPIs like employee engagement, turnover, decision speed, and manager satisfaction post-reorg. These can provide early warning signs if spans are too wide or teams are struggling.


5. Communicate clearly and consistently

Structural changes can breed uncertainty. Communicate not just what is changing, but why, and how it will improve the experience for both managers and their teams.


Structure Should Enable Strategy


A reorganization is not just a reshuffling of boxes on an org chart, it’s an opportunity to realign your workforce with your business goals. But even the most visionary strategy will falter if leaders are overwhelmed, disengaged, or unsupported.


As the research shows, successful reorgs pay close attention to the human factor. Avoiding overly wide spans of control is not about bureaucracy; it’s about enabling leaders to lead.


By Effie Zimmerman May 21, 2026
Chief Financial Officer ABOUT THE COMPANY  Milwaukee Electronics (MEC) was founded in 1954, offering services in circuit board design and PCBA assembly to the mining industry in the Wisconsin, USA, region. Michael Stoehr purchased the company in 1985 with the mission of creating a business that would put customers first and be a fulfilling place to work for the employees serving those customers. MEC has since grown into an international organization with locations in Wisconsin, Oregon, Mexico, India, and Singapore, serving a multitude of industries and customers from Fortune 50 companies to small, privately held organizations. Jered Stoehr is the second generation to take the Chief Executive helm, carrying on his father’s customers-first legacy and ensuring that MEC maintains the entrepreneurial spirit that has allowed the company to continually expand its range of services, maintain decades-long customer relationships, and provide careers for many dedicated employees. Our services include: End-to-end electronics manufacturing services, including PCBA, box build, and test Program management, including supply chain and logistics management Quick-turn prototype and on-demand manufacturing Our Mission is Acceleration. For customers, we bring innovations to life from prototype to production. We turn their vision into reality and accelerate what’s possible through partnership, a commitment to quality, and flexible processes. For employees, we create opportunities to grow and change. Through continuous learning programs, internal promotions, and a culture of personal care, we accelerate the cycle of abundance for our people and our communities. Our 70+ years in electronics innovation is powered by our incredible people, from the factory floor to the corporate office, who bring this mission to life each day. POSITION SUMMARY The Chief Financial Officer (CFO) reports directly to the CEO and is a key member of the executive leadership team, responsible for all aspects of financial management, strategy, and performance. The CFO partners closely with operations, supply chain, and commercial leaders to align financial goals with manufacturing objectives while ensuring compliance, efficiency, and sustainable growth. This role requires an experienced finance leader with strong knowledge of manufacturing operations, cost accounting, and global business practices. The CFO will provide strategic financial guidance, manage risk, and ensure the company has the resources and insights to achieve its objectives. Essential Duties and Responsibilities Strategic Leadership Serve as a strategic partner to the CEO, President, executive team, and board of directors, providing insights on growth, profitability, and sustainability. Develop and execute financial strategies that support long-term business objectives. Provide recommendations on operational efficiency, capital allocation, and expansion opportunities. Maintain a strong relationship with financing partners. Development of financial plans and forecasts, capital expenditure plans, budgets, cashflow forecasts and covenant forecasts. Financial Management & Reporting Oversee domestic and international financial operations, including accounting, reporting, tax, and treasury functions. Ensure accuracy, timeliness, and compliance of financial reporting under U.S. GAAP and local statutory requirements in Mexico, India, Singapore, and other jurisdictions. Lead preparation and presentation of financial results, KPIs, and dashboards for executive leadership and stakeholders. Work with the outside CPAs for successful financial audit and tax reporting. Operations & Cost Management Partner with manufacturing leaders to monitor operational performance and key cost drivers. Oversee cost accounting, inventory valuation, and margin analysis to support informed decision-making. Drive initiatives that enhance efficiency, reduce costs, and improve profitability across global operations. Lead the relationships with the benefit providers, 401k, self-insured health and dental, disability and life. Maintain a competitive benefit package that is cost-effective. Contracts, Risk & Compliance Manage and negotiate the business insurance package. Negotiate, review, and manage NDA’s and contracts with customers, vendors, and service providers. Ensure compliance with federal, state, and international financial and tax regulations. Strengthen internal controls and risk management practices across the organization. Team Leadership & Development Lead and mentor the finance team, including a Director of Finance, Corporate Controller, and the corresponding accounting teams. Foster a culture of accountability, collaboration, and continuous improvement. Develop team capabilities to support evolving business needs. Global Responsibilities Oversee domestic and international financial operations, ensuring compliance with U.S. GAAP and local statutory requirements in Mexico, India, Singapore, and other jurisdictions. Manage global tax strategy, including transfer pricing, cross-border compliance, and coordination with external auditors and advisors. Drive consistency in financial practices, systems, and reporting across all locations while respecting local requirements. Collaborate effectively across diverse geographies, time zones, and cultures to ensure alignment and accountability. KEY PARTNERSHIPS The CFO will collaborate across the organization to bridge finance with operations, including: Operations & Manufacturing – Partner with Plant General Managers, Supply Chain, Logistics, and Quality teams to manage production performance, cost drivers, and efficiency improvements. Engineering & Product Development – Collaborate with R&D and Process Engineering on new product investments, process improvements, and automation initiatives. Commercial Functions – Support Sales, Business Development, and Program Management with pricing strategy, contract terms, revenue forecasting, and customer profitability. Corporate Services – Align with HR on labor costs and workforce planning, IT/ERP on systems and reporting integration, and Legal on contracts, risk, and compliance. Executive Leadership & Board – Partner with the CEO and board of directors to provide insights on financial performance, growth opportunities, and long-term strategy. QUALIFICATIONS Bachelor’s degree in Accounting, Finance, or related field required; CPA with 5+ years of professional experience required. MBA or CMA strongly preferred. 15+ years of progressive finance experience, including 5+ years in a senior leadership role. Proven expertise in manufacturing finance, including cost accounting, margin analysis, and operations support. Demonstrated success in contract negotiation, risk management, and global financial operations, including multi-site, international entities. Experience in mid-sized companies ($100M–$250M revenue) and familiarity with scaling finance across multi-site global operations preferred. Strong executive communication skills with the ability to influence across functions, geographies, and cultures. Hands-on, detail-oriented leader with a strategic mindset, adaptability, and integrity in a fast-paced environment. Key Competencies Strategic, financial, and analytical thinker with proven ability to align financial strategy to business goals Deep understanding of manufacturing operations, cost structures, and operational performance drivers. Strong business acumen with demonstrated negotiation and partnership skills. High integrity and commitment to ethical practices Collaborative leadership style with a focus on developing people and building high-performing teams. Advanced data analysis skills and systems expertise, including ERP and CRM platforms, business intelligence tools, and Excel, with the ability to translate data into actionable insights. Interested in Learning More? 180one has been retained by Milwaukee Electronics to manage this search. If interested in learning more about the opportunity, please contact Tom Haley / 503.334.1350/ tom@180one.com .
By Greg Togni May 7, 2026
Hiring executives from large, high-performing organizations is one of the most common and most misunderstood moves smaller companies make. The logic is simple: if someone has seen “good” at scale, they should be able to bring it with them. In practice, that translation is far less reliable than most boards and CEOs expect. External executive hires, especially those coming from larger or more prestigious companies, fail at high rates. Numbers vary by study, but many put it around the 40–50% range within the first 18 months, with many more underperforming relative to expectations. The issue usually isn’t raw capability. It’s a mismatch between what made someone effective in their last environment and what this environment actually requires. The appeal of “importing excellence” Boards and CEOs often look externally when they want a step-change. A well-known resume signals ambition and can feel like a shortcut to stronger execution. The hope is that leaders from big companies bring: Repeatable operating patterns Experience with scale and complexity High standards and disciplined cadence That logic can be right in moments like rapid growth or expansion, but it breaks when we assume success is automatically portable across contexts. The portability problem Executive transitions fail most often because of context. What “good” looks like is shaped by culture, incentives, decision norms, and informal power, things that are hard to see from the outside. Big-company leaders can bring frameworks and processes, but they can’t import the conditions that made those tools work, mature systems, brand leverage, deep benches, and established trust. When the environment changes, the old playbook can fail. Why external hires fail When an external executive hire goes sideways, the causes are usually predictable: Cultural mismatch: misreading decision-making, conflict, and what’s truly rewarded. Weak relationship ramp: focusing on strategy before building alignment and trust. Over-reliance on prior supports: assuming budgets, systems, brand, and staffing that aren’t there. Misaligned expectations: different assumptions about mandate, pace, resources, and autonomy. Organizational resistance: skepticism of outsiders magnifies early mistakes. A flawed premise (on its own) In reality, what counts as “good” is highly situational. It’s shaped by a company’s stage, structure, market position, and culture. An executive who thrived in a large, stable organization may struggle in a fast-moving, ambiguous environment - not because they lack skill, but because the definition of success has changed. This doesn’t mean hiring from large organizations is a bad strategy. It means the strategy is often applied too simplistically. When it works (how to hire successfully) External hires tend to succeed when there’s a genuine match between past experience and current needs, not just in industry or function, but in context. Leaders who have navigated similar stages of growth or similar organizational constraints are far more likely to adapt effectively. Smaller and earlier-stage companies require different “muscles”: operating with constraint, making decisions with incomplete data, and building systems from scratch. Hiring from large organizations can be a great strategy if you also screen for those portability skills. Success also depends heavily on onboarding and integration. Companies that treat executive transitions as a structured process, focused on relationships, context-building, and expectation alignment, see much better outcomes. Perhaps most importantly, both sides need to approach the transition with humility. Executives must be willing to question their assumptions and adapt their playbooks. Organizations must recognize that even highly capable leaders need time and support to understand how things actually work. The takeaway Hiring executives from large organizations isn’t misguided. But the belief that success can simply be transplanted is. Leadership effectiveness is not just about what someone knows; it’s about how well they can interpret and respond to a specific environment. Without that alignment, even the most impressive resumes can lead to disappointing results. The real challenge isn’t finding leaders who have seen excellence. It’s finding those who can recreate it under entirely different conditions.
By Effie Zimmerman May 5, 2026
180one is pleased to announce our recent partnership with Globe Machine and the resulting hire of their new Board Member For over a century, Globe Machine Manufacturing Company has been at the forefront of delivering custom-engineered factory solutions for manufacturers. Our solutions combine decades of proven mechanical performance with cutting-edge automation, controls, and robotics, empowering our customers to achieve next-level operational efficiency. Globe Machine was acquired by Westward Partners in 2024. Westward Partners is a Seattle-based private equity firm investing in lower-middle-market businesses across a variety of industries in the Pacific Northwest. The acquisition will set Globe up for accelerated growth and help the Company better serve new and existing customers through innovation, training, parts, and service – something it has done successfully for over a century. Congratulations to Globe Machine and the 180one Search Team on a successful executive placement!
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