Episodios
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My guest for Episode #518 of the Lean Blog Interviews Podcast is Jerry Wright, author of the new book The Insanity Trap: What Your MRP Consultant Won't Tell You.
Jerry M. Wright, PE, MBA, is an accomplished operations executive and teaching professional with over 39 years of experience in the manufacturing and service sectors.
His extensive career spans various industries, including aerospace, consumer goods, healthcare, medical devices, diagnostics, and industrial sectors, where he has held leadership roles in engineering, operations, quality assurance, and operational excellence (OpEx).
He is an expert on taking businesses from MRP "insanity" to Pull Systems (Kanban) and driving operational excellence through the implementation of Toyota Production Systems (TPS/Lean) tools and methods.
He's a Master Black Belt and only the 7th person in the world to receive the Lean Gold Certification (LGC) from the joint alliance of ASQ, AME, SME, and the Shingo Institute.
In this episode, Jerry shares his insights and hard-earned lessons about the pitfalls and inefficiencies of Material Requirements Planning (MRP). Jerry reflects on his career, starting with his early Lean experiences at Kimberly Clark, where he encountered the challenges of forecasting, production scheduling, and the recurring "insanity trap" of MRP. He discusses the implementation of Kanban systems, the impact on inventory management, and how turning off MRP systems helped teams dramatically reduce shortages and excess inventory.
Through real-life examples, Jerry illustrates how companies can shift from traditional MRP-driven processes to more effective demand-driven and Kanban-based systems, leading to operational improvements, better employee engagement, and more reliable supply chains. The episode also touches on the psychology of change management, navigating the resistance from those invested in outdated systems, and how leadership can foster a more adaptive, efficient environment by embracing simplicity over complexity.
Questions, Notes, and Highlights:What is your Lean origin story? Were your parents open to Kaizen opportunities or suggestions from you as a child? Was your first introduction to the "insanity trap" of MRP at Kimberly Clark? Can you describe the challenges of dealing with MRP at Kimberly Clark? What was Bill Holbrook's role when he suggested unplugging the MRP? How did your team transition from MRP to Kanban, and what were the results? Can you explain the issues with relying on forecasts and lead times in MRP systems? What do you think about demand-driven MRP as an alternative? Why do you think demand-driven MRP isn't more widely adopted? How do you balance the risk of excess inventory versus lost sales? How did Dell handle material constraints and lead time reduction when you were there? How does Toyota manage its supply chain and production planning without relying heavily on MRP? Can you talk about how Toyota's system recovers quickly from supply chain disruptions? What was the origin of your book The Insanity Trap? How can leaders and companies overcome the psychological barriers to changing their supply chain systems? How do you help employees transition from roles like expediting to managing Kanban systems? What are your thoughts on the promise of AI in demand forecasting and supply chain management? Who is the target audience for your book? What are your thoughts on supply chain planning versus execution in lean environments?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for this bonus episode of the Lean Blog Interviews Podcast is Bruce Hamilton, who is joining me on the show for the first time. Bruce is a renowned figure in the Lean world, serving as the President of GBMP Consulting Group and Director Emeritus for the Shingo Institute.
As a senior examiner and certified workshop facilitator for the Shingo Prize, Bruce brings a wealth of knowledge and experience. He is also a past recipient of the Shingo Prize in both business and academic categories and has been inducted into both the Shingo Academy and the AME Manufacturing Hall of Fame.
During our conversation, Bruce reflects on two major milestones: the 25th anniversary of the now-classic "Toast Kaizen" video and the 20th year of GBMP's Northeast Lean Conference. He shares the humble beginnings of "Toast Kaizen," filmed in his kitchen with the help of his two-month-old son, and its unexpected success. We also discuss the evolution of the Northeast Lean Conference, from its modest start to an event that now attracts Lean thinkers from across the country. Bruce talks about the upcoming conference theme, âLeveraging Lean to Thrive,â and how Lean principles can help organizations overcome uncertainty, especially in todayâs challenging times.
The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for Episode #517 of the Lean Blog Interviews Podcast is Jacob Stoller, a journalist, speaker, facilitator, and Shingo-Prize-winning author of The Lean CEO. We talked about that in Episode 221.
Episode page with video, transcript, and more
His latest book, Productivity Reimagined: Shattering Performance Myths to Achieve Sustainable Growth, was just released by Wiley on October 8th, 2024.
Jacob has published hundreds of articles on technology and business management methods, and is known for demystifying complex topics for general business audiences. Jacob has delivered a variety of keynote speeches and learning events workshops in Canada, Europe, and the US, and authored reports, created training materials, and strategic corporate documents for clients such as Microsoft, Dell Computer, Staples, Pitney Bowes, International Data Corporation (IDC), CMA Canada, and the Conference Board of Canada.
In this episode, the discussion focuses on debunking common myths about productivity and exploring how sustainable growth can be achieved by improving operational efficiency without sacrificing quality. Jacob emphasizes the importance of lean thinking and continuous improvement, noting that productivity gains should come from enhancing processes, not just relying on technology or financial measures. We also highlight the critical role of people and culture in driving lasting improvements and discuss how true productivity involves creating more value with the same or fewer resources, aligning with lean principles.
Questions, Notes, and Highlights:What have you been up to since The Lean CEO? If you were to do a new edition of The Lean CEO, what would you add? How do you define productivity? What are productivity myths, and how are they affecting organizations? What are some examples of productivity gaps you've observed in industries like manufacturing? What misconceptions exist about improving productivity with lean methodologies? How important is the people side of lean, and how does it impact productivity? What strategies have you found most effective for real employee engagement? What are the pitfalls or misconceptions around leveraging technology for productivity gains? Can you share examples of companies successfully using lean thinking to improve productivity? What are some success stories or inspiring examples of organizations improving productivity outside traditional lean environments?Key Topics:Productivity myths and misconceptions The relationship between productivity, quality, and resource efficiency The importance of the people-first approach in lean Challenges in sustaining lean improvements The role of technology and automation in productivity Leadership's role in driving cultural change and continuous improvement The evolving landscape of productivity in various sectors, including manufacturing, healthcare, and sustainability.The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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In this episode of Lean Blog Interviews, Mark Graban welcomes Roberto Priolo, the Managing Editor of Planet Lean, the publication of the Lean Global Network. Based in Barcelona, Roberto has a background in journalism and extensive experience in covering Lean and continuous improvement topics. Mark and Roberto discuss the upcoming Lean Global Connection event, happening on November 21st and 22nd, 2024, which is a free, 24-hour virtual event designed to bring together the global Lean community.
Episode page with transcript, video, and more
Key Topics Discussed:The Origins of the Lean Global Connection Event: Roberto explains how the event began during the pandemic as a way to connect Lean practitioners worldwide when in-person gatherings were impossible. Now in its fourth year, the event continues to thrive, attracting speakers and attendees from over 120 countries.What to Expect at the 2024 Event: This yearâs theme, âDeveloping Adaptiveness in a Changing World,â addresses how Lean can help organizations navigate complex challenges like supply chain disruptions, geopolitical issues, and emerging technologies like AI. The event will feature nearly 100 presentations, spanning 24 hours, with thought leaders sharing real-world case studies, insights, and best practices.Speakers and Presentations: Mark and Roberto highlight key speakers such as Art Byrne, Jim Womack, John Shook, and many others from around the world. The event will also include external voices to help contextualize Leanâs relevance in a broader geopolitical and business landscape.Psychological Safety in Lean: Mark shares details about his presentation, which will focus on psychological safety as a foundation for continuous improvement. He will explore how creating environments where employees feel safe to speak up about problems and ideas is crucial for effective Kaizen and strategy deployment.The Lean Social Side: Roberto emphasizes the importance of the "social side" of Lean, which often gets overlooked in favor of technical tools. He stresses the need for reinforcing this message continually within the Lean community to ensure organizations foster environments that prioritize human interaction and psychological safety.Additional Insights:The Event Format: The Lean Global Connection is designed as a global festival of Lean thinking, running for 24 hours straight, with two stages running simultaneously. Attendees can join at any time and catch up later with recorded sessions available on the Lean Global Network YouTube channel.Robertoâs Lean Journey: Roberto shares his journey from studying journalism in London to becoming a central figure in the Lean community, managing Planet Lean and contributing to the Lean Global Networkâs mission of spreading Lean thinking.How to Join:Register for the free Lean Global Connection event here. Mark your calendar for November 21st and 22nd, and be sure to check out previous yearsâ presentations on the Lean Global Network YouTube channel for a taste of whatâs to come.
Resources Mentioned:Planet Lean website: Link to Planet LeanLean Global Network YouTube channel: Link to YouTube ChannelEvent Registration: Link to Event PageTune in for this exciting conversation with Roberto Priolo to learn more about how the Lean Global Connection continues to bring the worldâs Lean community together and what to expect in this yearâs event.
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My guest for Episode #516 of the Lean Blog Interviews Podcast is Jenn Christison, founder and principal consultant at Seven Ways Consulting.
Episode page with video, transcript, and more
Jenn has spent more than 15 years leading continuous improvement efforts across a variety of industries, including aerospace manufacturing, healthcare, non-profit, pharma, and tech. Guided by the principles of Respect for People and Continuous Improvement, Jenn brings a wealth of experience to her work, helping organizations achieve meaningful transformation.
Jennâs journey began with a desire to change the world as a teacher, social worker, or stand-up comedian. discovered my biggest impact could be made leading organizational transformation.
Jenn is also the author of the new book Even Better Leadership: Provocative Reflections to Guide Improvement and continues to embrace her stand-up comedy roots â if you know where to look. Weâre thrilled to have her on the show today to share her insights and experiences.
In this episode, Jenn shares her journey from aerospace and defense at Boeing to leading Lean and continuous improvement efforts in healthcare and beyond. We discuss Jenn's Lean origin story, how her early experiences as a teacher, social worker, and stand-up comedian influenced her approach to leadership and transformation, and the lessons sheâs learned from working in various industries. Jenn also talks about her new book, Even Better Leadership: Provocative Reflections to Guide Improvement, and the iterative process behind its creation. Additionally, we explore the challenges of applying Lean in healthcare and the importance of prioritizing quality and respect for people in organizational improvement.
Questions, Notes, and Highlights:Can you tell us your Lean origin story? How do lessons from being a teacher, social worker, and stand-up comedian shape your approach to transformation? What inspired you to write your new book, Even Better Leadership? How did you transition from aerospace to healthcare, and what sparked your interest in that shift? What are your thoughts on Boeingâs recent struggles, especially on the commercial side? What were some challenges and surprises you encountered when applying Lean in healthcare? Can you share a favorite example of a successful Lean improvement at Seattle Childrenâs? What led you to start your consulting firm, Seven Ways Consulting, and how does being an external consultant differ from working internally? What is the meaning behind the name 'Seven Ways Consulting'? What was the iterative process like for developing your book?What insights did you gain from working in various industries that you apply to leadership and improvement today?
The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for Episode #515 of the Lean Blog Interviews Podcast is Jim Morgan, senior advisor at Lean Enterprise Institute and a board member at Adrian Steel. Jimâs most recent industry experience was as Chief Operating Officer at Rivian, an electric vehicle manufacturer.
Episode page with video, transcript, and more
He was previously a guest in Episode 109 back in 2011.
Before joining Rivian, Jim spent a little over ten years at Ford Motor Company. He began by leading the development of the Global Product Development System (GPDS).
He then served the last nine years as Director of Global Body and SBU Engineering and Tooling operations, where he and his team contributed to the companyâs historic, product-led revitalization under then-CEO Alan Mulally.
Prior to Ford, Jim served as Vice President of Operations at Troy Design and Manufacturing (TDM), a tier-one global automotive supplier of engineering services, prototype tools, and low to medium-volume production parts and subassemblies.
Jim holds a Ph.D. in Engineering from the University of Michigan, where his original research into Product Development won two Shingo Prizes for Research Excellence. In addition, he co-authored (with Professor Jeffrey Liker) the award-winning books The Toyota Product Development System (2006) and Designing the Future (2018).
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Weâll dive into his incredible journey, from his time at Ford, where he led the development of their global product system, to his work at Rivian, helping to shape the future of electric vehicles. Jim shares valuable lessons learned along the way, especially around integrating lean principles into product and process development. We also talk about how embracing risk and learning from mistakes can fuel innovation.
Questions, Notes, and Highlights:Lean Origin Story: Whatâs your lean origin story, and how did you get introduced to lean thinking? Product Development vs. Production: Can you explain the difference between product development and production systems? Rivian Involvement: How and when did you get involved with Rivian, and what drew you to the company? Challenges at Rivian: What were the major challenges and opportunities as Rivian evolved from concept to production? Recruiting for Rivian: How did you recruit talent for Rivian, and what was the mix of automotive and non-automotive experience? Rivianâs Product Strategy: How did Rivianâs product strategy differ from other electric vehicle manufacturers like Tesla? Culture Development: How did Rivian focus on building its own culture and operating system from the ground up? Learning from Mistakes: How did Rivianâs culture embrace learning from mistakes, and how was that risk tolerance cultivated? Ford and Alan Mulallyâs Leadership: How did Alan Mulallyâs leadership at Ford influence your thinking on surfacing and solving problems? Board Involvement: What has your experience been like as a board member at Adrian Steel, and how does it differ from your previous roles? LEI Learning Groups: Can you tell us about the LEI Product and Process Development Learning Group and how companies collaborate and learn together? Designing the Future: Whatâs the central message of your book Designing the Future, and who is the target audience? Agile and Lean Integration: How are you integrating agile and lean practices, especially in product and software development?Key Topics:Jimâs introduction to lean via The Machine That Changed the World. Differences between lean product development and lean production systems. Jimâs role at Rivian and the companyâs approach to electric vehicle manufacturing. Rivianâs unique culture and the importance of building the âRivian Way.â Challenges in launching new vehicles and managing diverse teams. Importance of learning from failure and embracing risk at Rivian. Lessons from Alan Mulallyâs leadership style at Ford. Jimâs board experience at Adrian Steel and how it differs from operational leadership. Collaborative learning through LEIâs Product and Process Development Learning Group. The integration of agile and lean principles for better hardware-software development alignment.The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for Episode #514 of the Lean Blog Interviews Podcast is Hugh Alley, an author and consultant. He divides his time between coaching senior operational leaders in continuous improvement, training front-line leaders in core supervisory skills, and designing industrial facilities.
An industrial engineer, he has run three manufacturing and distribution firms, and a department in a government agency, teaching skills to over 1,000 front-line leaders.
He has written two books: Becoming the Supervisor: Achieving Your Company's Mission and Building Your Team, and The TWI Memory Jogger.
He frequently speaks about supervision, quality, lean manufacturing, and Toyota Kata. From his home near Vancouver, Canada, he helps clients across North America.
In today's episode, we explore the power of TWI (Training Within Industry), its impact on building trust and improving workplace culture, and stories of real-world applications in manufacturing and sports. From reducing cycle times to fostering better leadership, this episode covers key lessons in Lean methodology. Tune in to hear about Hugh's Lean origin story and his experiences in applying Lean principles across various industries. Don't miss out on a thoughtful discussion that blends Lean, leadership, and even hockey!
Questions, Notes, and Highlights:What kind of government agency did you work for? How did you reduce lead times for occupational disease claims? What is your lean origin story? Where, when, and why were you introduced to lean? Was the word "Kaizen" used in your early lean experiences? Is job relations typically the starting point in TWI, or does it depend on the culture? What parallels do you see between sports coaching and leadership in the workplace? How can you tell if a workplace problem is due to tactics, teamwork, or culture? What role does continuous improvement play in sports teams' success, and can it happen game to game? How do you see the role of fear in leadership and coaching, and what impact does removing a "bully" leader have on a team? How can job instruction and job relations contribute to better workplace culture and performance? How do you approach the challenge of hiring the right people and fitting them into a lean system? How did TWI help one of your clients shorten training times and reduce bad product? What opportunities do you see for companies to create "practice days" similar to sports teams? How do you convince leaders to care about improving their supervisors' skills? What role does a coach or leader play in creating the right context for their team to succeed? What do you think makes a great player transition into a great coach? How do you use the TWI model to break down jobs and help people learn faster? What's your take on benchmarking against others in the industry? How did you help reduce patient waiting times in a medical lab by aligning priorities? Was Wayne Gretzky's coaching career unsuccessful, or did he just pick the wrong job? How do you translate great skills into effective coaching, and how does TWI help with that?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guests for Episode #512 of the Lean Blog Interviews Podcast are two of three co-authors of the upcoming book âLeading Excellence: 5 Hats of the Adaptive Leaderâ - Brad Jeavons and Stephen Dargan.
Episode page with video, transcript, and more
Stephen Dargan
A diverse and inclusive, customer-centric, driven transformational leader with 20+ years of leadership experience spanning Australia and Europe. Stephen is a Shingo Institute Alumni, Shingo Facilitator and Examiner. He is a graduate of the Australian Institute of Company Directors and a certified Lean Six Sigma Black Belt.
Brad Jeavons
Brad Jeavons is a senior leadership coach focused on helping improve themselves and their organisations to create a better future economically, socially and environmentally for future generations. He is host of the Enterprise Excellence Podcast and Community and author of the book Agile Sales: Delivering Customer Journeys of Value and Delight. Brad was a guest back in episode 416, June 2021.
In this episode, Brade and Steve share insights into the key concepts of adaptive leadership, including the importance of understanding individual team members, cultivating psychological safety, and the five essential leadership hats: Inspire, Train, Support, Coach, and Direct. Brad and Stephen also discuss real-life applications, the significance of leadership shadow, and the critical role of serving the growth of others to drive organizational excellence.
Questions, Notes, and Highlights:What are some factors contributing to low employee engagement? Can you elaborate on the concept of the leadership shadow and its impact? What behaviors help cultivate psychological safety and engagement? What does it mean to be a leader who serves, and why is it important? How can leaders develop the ability to be adaptive or situational? What are the five hats referenced in the subtitle of your book? Why is controlling emotions crucial for leaders, and how can they improve this skill?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guests for Episode #512 of the Lean Blog Interviews Podcast are Steve Pereira and Andrew Davis, authors of the new book Flow Engineering: From Value Stream Mapping to Effective Action.
Blog post with video, transcript, and more
Steve Pereira has spent over two decades improving workflow across various organizations. His experience spans tech support, IT management, platform and infrastructure engineering, product management, and serving as a founding CTO for an enterprise SaaS company. Currently, he is the CEO of Visible Consulting, COO of the Value Stream Management Consortium, and co-founder of the Flow Collective.
Andrew Davis is the Chief Product Officer at AutoRABIT and the author of "Mastering Salesforce DevOps." With a background as a Salesforce architect, developer, and product leader, Andrew focuses on the human side of software development. He spent 15 years as a Buddhist monk, teaching meditation and personal transformation, and now studies the intersection of business, technology, and psychology through systems thinking.
In this episode, we discuss the principles of flow engineering, the importance of psychological safety in process improvement, and their experiences in writing the book. We also dive into their personal journeys, inspirations from industry giants like Deming and Goldratt, and the challenges and lessons learned in collaborative work. Stay tuned for a deep, insightful conversation on enhancing workflows and fostering a culture of continuous improvement.
Questions, Notes, and Highlights:Can you discuss the relationship between making mistakes and learning from a Buddhist perspective, Andrew? Why do you resonate with figures like Deming, Goldratt, and Ackoff in your improvement work, Steve? How did you two end up collaborating on the book? Did you apply flow engineering concepts to the development and writing of the book together? How did the process of writing the book evolve over time? What lessons did you learn about collaboration and flow from writing this book? How does psychological safety impact value stream mapping and flow engineering? How do you involve workers in process design to avoid negative perceptions of imposed processes? What challenges did you face in maintaining a regular cadence of work while writing the book?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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In this special live-streamed bonus episode of the Lean Blog Interviews podcast, host Mark Graban is joined by Paul Critchley for an impromptu experiment in recording a live podcast. The episode begins with a brief introduction and a discussion about the decision to try a live format.
Paul Critchley, a seasoned Lean consultant, shares his background, detailing his journey from a mechanical engineer in the automotive industry to his current role as a Lean practitioner and consultant. He highlights his experiences working with Toyota and Pratt & Whitney, emphasizing the practical application of Lean principles in various industries, including aerospace.
Summit info: https://newenglandleanconsulting.com/summit/
The conversation then shifts to Paul's upcoming event, the New England Lean Summit, scheduled for September 12-13, 2024, in Cromwell, Connecticut. Paul discusses the summit's agenda, which includes workshops, sessions, and a Lean Happy Hour. He expresses his excitement about bringing together Lean professionals from diverse industries to foster learning and networking in a fun and engaging environment.
Paul also introduces the New England Lean Collaborative, a member-based organization aimed at building a community of Lean practitioners in the New England region. He explains the collaborative's activities, such as book clubs, site tours, and resource sharing, designed to facilitate continuous learning and improvement.
The collaborative: https://newenglandleanconsulting.com/the-nelc/
The episode wraps up with Mark and Paul addressing a viewer's question about implementing Lean practices in small companies with limited resources. Paul advises starting small, focusing on incremental improvements, and maintaining momentum through continuous, manageable changes.
Throughout the episode, Paul emphasizes the importance of creating a psychologically safe environment for learning and experimenting with Lean practices, highlighting the benefits of fun and engagement in the process. The episode concludes with a reminder of the event details and an invitation for listeners to join the New England Lean Summit and Collaborative.
00:01:24: Guest Introduction - Paul Critchley
00:03:00: Paul's Career Background
00:03:39: Discussion on Practicing Lean - https://practicinglean.com/
00:05:02: New Projects and Endeavors
00:05:29: New England Lean Summit Introduction
00:06:08: Details about the New England Lean Summit
00:07:04: Summit Logistics and Activities
00:09:02: Lean Happy Hour Concept
00:10:00: Hope for Future Annual Events
00:10:19: Overview of the New England Lean Collaborative
00:11:00: Functioning of the Collaborative
00:11:42: Membership Benefits and Activities
00:12:48: Discussion about Industry Participation
00:14:23: Lean Tools and Concepts
00:15:23: Connection with Bob Rush and Workshop Details
00:16:36: Fun Activities Planned for the Summit
00:17:01: Emphasizing fun and networking at the summit
00:17:39: Lessons from Pascal Dennis at Toyota
00:18:31: Incorporating a DJ at the conference
00:19:48: Creating a relaxed and engaging atmosphere
00:21:02: Unique conference experiences
00:22:00: Opportunities for
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My guest for Episode #511 of the Lean Blog Interviews Podcast is Sam Yankelevitch, a distinguished global operations executive who has dedicated his career to advancing Lean principles, effective communication, and innovative problem-solving. Sam's journey began with managing international projects and optimizing processes in various industries. His expertise and passion for continuous improvement have made him a sought-after speaker, workshop trainer, and corporate coach.
Episode page with video, transcript, and more
Sam is one of the speakers and facilitators at the upcoming Global Lean Summit Event, being held in Indiana this September.
Since 2014, Sam has leveraged his vast knowledge by producing popular online courses that have reached over 500,000 students worldwide. His contributions to LinkedIn Learning include highly-regarded courses such as "Root Cause Analysis" and "Improve Communication Using Lean Thinking." Sam's ability to distill complex concepts into actionable insights has earned him a dedicated following among professionals seeking to enhance their skills.
In addition to his educational endeavors, Sam recently ventured into fiction writing with his debut book, An Interview with Failure. This unique narrative explores the lessons learned from setbacks and the value of embracing failure as a stepping stone to success.
Before establishing himself as an influential educator and author, Sam held several key positions, including Vice President and General Manager at a German-based automotive supplier and President and CEO of Ideace, Inc., an international manufacturer and exporter. His diverse background and hands-on experience provide a rich foundation for his teachings.
Sam holds an Industrial Engineering degree and an Executive Master's in Financial Management, further solidifying his expertise in operational excellence and strategic leadership.
In this episode, we discuss the pivotal role that effective communication plays within the framework of lean thinking. We also explore how clear, concise, and consistent communication can significantly enhance problem-solving capabilities, streamline processes, and foster a culture of continuous improvement. Sam shares his insights on the common communication pitfalls that organizations face and offers practical solutions to overcome these challenges using lean methodologies.
Additionally, we preview Sam's upcoming workshop at the Global Lean Summit, where he will be leading a session on lean communication. This workshop aims to equip participants with hands-on tools and techniques to improve communication within their organizations. Attendees will learn how to adapt lean principles to enhance clarity, reduce misunderstandings, and ensure that everyone in the organization is on the same page, thereby driving better results and fostering a more collaborative work environment.
Questions, Notes, and Highlights:Tell us about the workshop you're doing at the Global Lean Summit. What are some core communication problems that Lean thinking addresses? Can you explain the concept of operational definitions from Dr. Deming? How can Lean methods improve communication in an organization? What's your lean origin story? How did your international experience influence your Lean approach? What were some challenges you faced when implementing Lean in the automotive industry? What advice would you give to someone leading a Lean transformation? How do you reframe failure as a learning opportunity? Can you tell us about your book, "An Interview with Failure"? How do you build trust in a coaching relationship? What's the importance of commitment conversations in leadership? How do you handle the word "accountability" in a positive way? How does communication serve as a precondition to quality? What can leaders do to improve their communication skills on the shop floor? What are the benefits of standard work and 5S in a high-mix, low-volume environment? How can Lean tools like Smed and Andon be applied to communication processes? What lessons have you learned about leading and motivating people throughout your career?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for Episode #510 of the Lean Blog Interviews Podcast is Karen Martin, Founder and CEO of TKMG and TKMG Academy, appearing for the fifth time.
Episode page with video, transcript, and more
She is the author of books including The Outstanding Organization, Clarity First, and Value Stream Mapping.
In this episode, we discuss mistake-proofing in lean practices, exploring its significance in various industries. The conversation begins with a light-hearted discussion about the "five-timers club" and Mark's "ZERO hat" from the Patient Safety Movement Foundation, which symbolizes the goal of zero harm in healthcare.
Karen shares her extensive background in quality improvement and lean management systems, emphasizing the importance of building quality at the source. Drawing on the teachings of Dr. W. Edwards Deming and the Toyota Production System, Karen and Mark discuss the psychological impact of striving for zero harm, debating whether it is an inspiring goal or potentially demotivating.
The episode also explores real-world examples of organizations achieving zero harm and the cultural shifts required to reduce errors. Karen introduces the TKMG Academy and its comprehensive courses designed to enhance lean practices, including the new mistake-proofing course co-developed with Mark. Her passion for quality improvement and continuous learning shines through, offering listeners valuable insights into achieving operational excellence.
Questions, Notes, and Highlights:Why is quality such a passion for you? Why did you want to add the mistake-proofing course to the TKMG Academy catalog? What are some common barriers to achieving zero harm in healthcare? How do you differentiate between mistakes and errors? How do you handle situations where the work system isn't at fault, but the individual continues to make mistakes? Can you tell us more about the "slow work" movement? What are your thoughts on final inspection versus quality at the source? How do you address the challenge of maintaining standards in training and process design? Could you elaborate on the spectrum of mistake-proofing from 100% prevention to error reduction? How does the TKMG Academy help organizations with continuous improvement?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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I'm very happy to be participating in Jared Thatcherâs âGlobal Lean Summitâ event this September in Indiana.
I'll be there to network and learn, which includes time visiting a Toyota Material Handling factory (an entire day!)
I'll be speaking and facilitating:
A workshop on Psychological Safety as a Foundation for continuous improvementA learning session featuring Dr. Deming's âRed Bead GameâA fun keynote talk on warning signs and mistake-proofingLearn more and register
Here's a 13-minute conversation that I had with Jared about the event.
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My guest for Episode #509 of the Lean Blog Interviews Podcast is Ankit Patel, the founder of My Business Care Team, a BPO company providing services for optometrists, and co-founder with his wife Classic Vision Care, an optometry group in Atlanta.
Episode page with transcript and more
With a strong background in Lean methodology, Ankit has worked as a Lean consultant at Dell and the Cleveland Clinic, driving process improvements and coaching executives.
He holds a Master's degree in Positive Organizational Development and a Bachelor's in Industrial Engineering.
Recognizing talent acquisition challenges, Ankit partnered with a Filipino team to source skilled, cost-effective staff for various business functions. He now leverages AI for hiring and automation to optimize his optometry practice and BPO services, applying Lean principles to drive efficiency and growth.
In this episode, Ankit shares insights from his journey, starting as a lean consultant at Dell and the Cleveland Clinic, and transitioning into optometry, where he focuses on building patient relationships and enhancing processes through lean principles and AI technology.
Mark and Ankit discuss the challenges and opportunities of integrating AI in business processes, the importance of positive organizational development, and how appreciative inquiry can drive team alignment and engagement. Ankit also highlights the role of the Entrepreneurial Operating System (EOS) in managing small businesses and improving training and development with AI tools, offering valuable lessons for anyone interested in continuous improvement and innovative approaches in healthcare and beyond.
Questions, Notes, and Highlights:What is positive organizational development, and how did you come to study it? How did your experience at Cleveland Clinic influence your involvement in your current business? How do you balance focusing on optometry with the potential to expand into other medical practices? How do you prioritize where to use AI in your processes without falling into the trap of using it because it's trendy? Can you share an example of improving a process before thinking about automating it with AI? How rapidly is AI technology advancing, and how does that impact your ability to adjust its use in your business? How do you see AI tools facilitating faster PDCA or PDSA cycles in continuous improvement practices? What led you to the positive psychology approach, and how does it differ from traditional organizational development? How do you apply appreciative inquiry in your work, and what impact does it have on team alignment and engagement? Can you discuss the origin and growth of your new business involving AI and BPO for optometry? What role does EOS (Entrepreneurial Operating System) play in managing your business? How do you evaluate the effectiveness of training and development using AI tools? How do you communicate your practice's focus on building patient relationships in your marketing and branding?The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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My guest for Episode #508 of the Lean Blog Interviews Podcast is Mike Hoseus, Executive Director of the Center for Quality People and Organizations and President of Lean Culture Enterprises.
Episode page with video, transcript, and more
He supports organizations in their lean journey, focusing on leadership and cultural aspects of the lean transformation. He is an adjunct professor with the University of Kentucky's Center for Manufacturing.
Michael Hoseus developed his TPS skills at Toyota Motor Manufacturing Kentucky, where he worked at the General Manager level in both Production and Human Resources, being mentored by his Japanese sensei. His Toyota process experience includes production, engineering, maintenance, safety, personnel, employee relations, benefits/payroll and training and development.
He learned first-hand how Toyota's success hinges on integrating their production and human systems to create the Toyota Way.
He's co-author, with Jeff Liker, of Toyota Culture: The Heart and Soul of the Toyota Way â which received the Shingo Publication Award in 2009
In this episode, Mike shares his extensive experience with Toyota, where he developed his TPS skills at TMMK in Georgetown, Kentucky. We take a deep dive into key topics such as the importance of psychological safety in lean leadership, the origins of the andon cord, and how to build a high-performance culture.
Mike discusses his journey from Toyota to helping other organizations with lean transformation, emphasizing the critical role of leadership in fostering a culture of continuous improvement. He shares insights on problem identification and problem-solving, the significance of respect and trust, and the intentional development of a lean culture.
Join us for this engaging conversation with valuable lessons and stories from Mike's career. Don't miss out on the chance to learn from one of the leading experts in lean culture and transformation.
Mike is also organizing a Kentucky learning tour, âHigh-Performance Culture and Lean Leadership,â from October 15 to 17⊠I'll be there and am very much looking forward to it. Use code GRABAN to save $500.
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My guest for Episode #507 of the Lean Blog Interviews Podcast is Wendy K. Smith, co-author of the book Both/And Thinking: Embracing Creative Tensions to Solve Your Toughest Problems. Sheâs also one of the keynote speakers at this year's AME (Association for Manufacturing Excellence) annual conference.
Episode page with video, transcript, and more
Enter to win a copy of the book!
Wendy is the Dana J. Johnson professor of management and faculty director of the Womenâs Leadership Initiative at the Lerner College of Business and Economics, University of Delaware.
She earned her PhD in organizational behavior at Harvard Business School, where she began her intensive research on strategic paradoxesâhow leaders and senior teams effectively respond to contradictory yet interdependent demands.
Working with executives globally, she has been a noted keynote speaker and teacher for audiences worldwide. Her research, published among the top journals in the field, has received numerous awards, including the Web of Science Highly Cited Research Award (2019, 2020, and 2021) for being among the one percent most-cited researchers in her field. Wendy lives in Philadelphia with her husband, three children, and the family dog.
In this episode, Wendy discusses strategic paradoxes and how leaders can effectively navigate contradictory yet interdependent demands. Our conversation covers practical examples from Lean Manufacturing and the Toyota Production System, highlighting how "both/and thinking" can lead to innovative solutions and improved performance. Wendy also shares the emotional and cognitive challenges of embracing paradoxes, offering insights into how organizations can create environments that support dynamic, integrative thinking. This episode is a deep dive into the nuances of leadership, organizational behavior, and the power of embracing complexity in problem-solving.
Questions, Notes, and Highlights:What are strategic paradoxes? The need or opportunity to break paradoxes? Good examples of both/and thinking in different businesses? Origins in lean manufacturing Just-in-time but hold no inventory High quality but also super fast Focusing on both short-term and long-term? Opportunities for startups to exploit new both/and thinking? Process as a dirty word in startups? We canât vs. we havenât figured it out yet? Both/and focus on customers and employees? Connections to Amy Edmondson and Psychological Safety? The Dr. Brian Goldman TED Talk Give us a preview of your keynote talk for AME? A teaserâŠThe podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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In this live stream episode, host Mark Graban introduces a panel of experts discussing the upcoming Future of People at Work Symposium. The event is co-sponsored by nine organizations, including the Lean Enterprise Institute, GBMP Consulting Group, and the Shingo Institute. Panelists Josh Howell, Bruce Hamilton, and Ken Snyder share their perspectives on the symposium's goals, emphasizing the need to address the evolving workplace and workforce dynamics. They highlight the importance of focusing on people in the face of technological advancements and the necessity of fostering a collaborative environment to adapt to future challenges.
The panelists provide an overview of the symposium's structure, which will include interactive sessions focused on workplace evolution, technology integration, and supply chain transformation. Unlike traditional conferences, this event aims for active participation, encouraging attendees to engage in collaborative problem-solving.
The speakers stress the importance of continued dialogue and collaboration within the lean and improvement communities to address the ongoing changes in the work environment. The symposium, set to take place in Detroit on July 18 and 19, 2024, is presented as a crucial step in creating a more meaningful and effective future of work.
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My guest for Episode #506 of the Lean Blog Interviews Podcast is Tim Hobbs, the founder and president of Hobbs Technical Consulting. He is an author and an in-demand international keynote speaker, trainer and business consultant. He is currently working in the semiconductor industry as a director of digital transformation.
Episode page with video, transcript, and more
Tim served nine years in the U.S. Navy, managing and maintaining advanced electronic navigational, alarm, combat, telecommunication and power systems. After his military service, he worked for Intel Corporation for 14 years.
He received a B.S. in business information systems and an M.B.A. in technology management and earned his Lean Six Sigma Blackbelt Certification.
Tim authored the book The Anatomy of Problem-Solving.
He'll also be one of the featured keynote speakers at the 40th anniversary of the AME International Conference (the Association for Manufacturing Excellence), being held in Atlanta, Georgia, from October 28 â October 31, 2024.
Enter a contest to win a free book and online course from Tim!
In this episode, Tim shares insights from his extensive career in the semiconductor industry, his journey through the US Navy, and his expertise in problem-solving. We discuss Tim's background, including his roles in digital transformation and Lean Six Sigma, and delve into his philosophy on critical thinking and structured problem-solving methods. Tim also previews his upcoming keynote at the conference, highlighting the importance of leveraging problem-solving for career success and organizational improvement. The conversation touches on his book, âThe Anatomy of Problem Solving,â and an exciting book giveaway contest for our listeners. Tune in to gain valuable insights into effective problem-solving and strategic career advancement from an industry expert.
Questions, Notes, and Highlights:Tell us about the start of your lean journey? Preview of your keynote talk? How do you combine frameworks and methodologies with critical thinking in problem-solving? Can you elaborate on organizational and political problem solving? Tell us about your online training program? What method are you using for problem-solving, and how did you develop it? What is the story behind your book, âThe Anatomy of Problem Solvingâ? What approach do you recommend for dealing with team dynamics in problem solving? How do you position problem solving for upward mobility in a career? Can you explain the PIE (Performance, Image, Exposure) framework and its importance in career advancement? What strategies do you suggest for engaging with potential sponsors? How do you handle the human element in problem-solving, especially when dealing with different personalities? Tim's online training programThe podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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This is cross-posted from my Lean Blog Audio podcast series.
Episode page with links and more infoâ
I'm very happy to announce the release of my new â Mistake-Proofing courseâ , available NOW through â Karen Martinâ and â TKMG Academyâ .
You can â buy the course individually at TKMGAcademy.comâ for $129. Volume discounts are available for large teams or your entire workforce (for more information, email â [email protected]â ).
The course is also part of the wonderful â collection of coursesâ in the all-access â annual subscriptionâ . The annual price of $529 goes up significantly at 11:59 pm CDT on May 31st, so act now for the best value pricing.
Other TKMG Academy â instructorsâ in the series include Karen Martin, â Elisabeth Swanâ , â Mike Osterlingâ , â Tracy O'Rourkeâ , â Brent Loescherâ ... and more.
And if you â subscribe to TKMG Academyâ , you can participate in Karen's "Community of Practice" meeting with me on Wednesday, June 26th.
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My guest for Episode #505 of the Lean Blog Interviews Podcast is Art Byrne, who was a guest back in Episode 158 about 12 years ago â we discussed his book The Lean Turnaround.
Episode page with video, transcript, and more: https://leanblog.org/505
Today, weâre discussing his new book, The Lean Turnaround Answer Book, an edited compilation of his âAsk Artâ columns published by the Lean Enterprise Institute.
Art Byrne has been implementing Lean strategy in various U.S.-based manufacturing and service companies, such as Danaher Corporation, for more than 30 years, including The Wiremold Company, which he ran for 11 years. He retired as an Operating Partner at the private equity firm J. W. Childs Associates L.P.
In this episode, Art revisits the podcast after twelve years to discuss his new book, The Lean Turnaround Answer Book, an edited compilation of his "Ask Art" columns from the Lean Enterprise Institute website. Art shares his extensive experience implementing lean strategies across various industries, including his notable work with Wiremold and his role in private equity at JW Childs Associates. The conversation also covers Art's motivations for writing his books and his continuous efforts to disseminate lean knowledge, addressing the practical challenges and questions that arise in Lean implementations.
Art elaborates on the essence of Lean principles, emphasizing the need for a fundamental shift in organizational philosophy and strategy. He recounts his experiences in transforming companies through Lean methodologies, including detailed anecdotes about reducing setup times, managing inventory, and improving operational efficiency. Art highlights the significant impact of lean on organizational performance, customer service, and financial health. The discussion also touches on the challenges of aligning traditional cost accounting with lean practices and the importance of engaging the finance department in the lean journey. Overall, Art's insights offer a comprehensive guide to Lean implementation, reinforced by real-world examples and practical advice.
Questions, Notes, and Highlights:Tell us about the book and how this one came to be⊠Cost accounting and inventory? Orry Fiume - âReal Numbersâ book The strategic value of setup reduction? How was Lean utilized in your private equity work? How was your role different as a PE partner? Looking for companies with a certain Lean potential? What factors are you looking for? Best Lean turnaround story? More likely a smaller PE company than a large public company? But Lean is not the default management approach for manufacturing? Higher than 10 years ago? Boeing - did they forget what Shingujitsu taught them? The problems caused by âmake the monthâThe podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.
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