In his latest article in Quality Digest, Don Wheeler celebrates the 100th anniversary of Shewhart’s control charts. He describes the use of these charts for process control as follows: “A baseline period is used to compute limits that define what a predictable process is likely to produce, and then these limits are used with additional […]

Quality management is essential for ensuring the efficiency and reliability of processes across various industries. Understanding and applying the right quality tools can significantly improve the achievement of optimal results. Let’s explore some key quality tools instrumental in process improvement and product quality assurance, along with examples for each. Acceptance Sampling Plan This tool helps […]

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on […]

Operational excellence is the continuous pursuit of improvement in an organization’s processes and systems to achieve efficiency, effectiveness, and agility. It involves streamlining operations, reducing waste, optimizing resources, and enhancing productivity to deliver high-quality products or services at lower costs and faster speeds. The impact of operational excellence on business growth is profound. By improving […]

We often see the phrase “People are our most important asset” on conference room walls, in company policies, annual reports, and frequently repeated by many so-called leaders. But can they prove it where it really counts—on their financial statements? Unfortunately, traditional GAAP and IFRS accounting make this very difficult. Many assets have clearly defined financial […]

Thanks, as always, to Ryan McCormack for this. He always shares so much good reading, listening, and viewing here! Subscribe to get these directly from Ryan via email. News, articles, books, podcasts, and videos about how to make the workplace better. Operational Excellence, Improvement, and Innovation Toyota admits to cheating on vehicle testing Toyota has […]

The Big Picture: In the Lean community and beyond, some people mistakenly equate “psychological safety” with being comfortable all the time. This misconception can undermine the true essence of psychological safety in the workplace. What Psychological Safety Really Means Psychological safety is not about constant comfort or shielding managers from discomfort. Synthesizing a few definitions […]

Introduction to Right First Time (RFT) Right First Time (RFT) is a critical manufacturing metric that emphasizes producing goods that meet quality standards on the first attempt without requiring rework. This principle is fundamental in Lean and Six Sigma methodologies, aiming to enhance efficiency, reduce waste, and ensure customer satisfaction. Organizations can significantly improve their […]

Things don’t get done unless people take responsibility. And in organizations, leaders and team members must take responsibility to move the vision, and the overall organization, forward. So, why do team members sometimes abdicate responsibility? What holds them back from stepping up when things are on the line? While the reasons can be numerous, here […]

In an era where efficiency and agility are paramount, Lean business transformation has emerged as a pivotal strategy for organizations aiming to streamline operations and enhance value creation. By adopting Lean principles, companies can significantly reduce costs, improve quality, and accelerate time-to-market. In today’s dynamic business environment, the Lean method is prized for its adaptability […]

Scroll down for how to subscribe, transcript, and more 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. She will also be one of the featured keynote speakers at the 40th anniversary of the AME […]

Transform Resistance Into Buy-In Are you struggling to get your senior team on board with your vision for change, to get buy-in for a new initiative, or to get leaders to sign on to your services as a coach or consultant? Good news. Leading through influence and persuasion can make this happen. In this episode, […]

In the increasingly complex and rapidly evolving world in which we operate, business transformation has become crucial for organizations striving to stay competitive and relevant. Business transformation refers to the fundamental and profound changes an organization undergoes to adapt to new market conditions, technological advancements, or shifts in consumer behavior. It encompasses many initiatives to reshape […]

I recently rediscovered a great quote from President John F. Kennedy. It was during Lehigh University’s commencement, where I was observing my daughter Emma’s graduation. The original quote is from Kennedy’s commencement speech at Yale University on June 11th, 1962, and was echoed by Lehigh’s President Joseph Helble in his remarks. The core of the […]

The second BMW plant I visited was in Leipzig. This modern greenfield plant had a very good material flow, where especially the finger line impressed me a lot. In terms of efficiency it was the best-performing plant in Germany, shortly after Munich, and on par with Toyota. It was also exceptionally clean. The only flaw […]

I’m excited that the Shingo Institute asked me to present a webinar on June 18th: Click here to register for the webinar They’ve also published an article that I wrote: Psychological Safety: The Key to Effective Andon Cord Pulls and Continuous Improvement The webinar description: Join us for an engaging webinar as we explore the […]

By Pascal Dennis (bio) Because it makes things small and personal — and thereby helps to dispel Big Company Disease. Big companies take themselves seriously. Laughter punctures the balloon and drenches things in the light of sanity. For organizations big & small, I’d say “embrace your inner smallness”. I give a talk called “Everything I […]

Projects are important for generating growth for organizations. Successful projects don’t just happen; they require hard work and collaboration from both project managers and team members to ensure all tasks are completed and goals are met, on time and on budget. However, many projects ultimately fail or are abandoned because the team does not work […]

Memorial Day is a valuable holiday to reflect on those that have served our Country. As we think about this holiday let’s also take a pause, practice a little mindfulness, and take stock of our behaviors. Because when it really comes down to it, our behaviors are all we truly have control over.  Whether in […]

A selection of highlighted blog posts from Lean bloggers from the month of May 2024.  You can also view the previous monthly Lean Roundups here.     Lean as Alternative Medicine – Bob Emiliani shares his thoughts on what he believes Taiichi Ohno might think of what Lean has become today and what he might say to […]

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on […]

For my Facebook fans you already know about this great feature. But for those of you that are not connected to A Lean Journey on Facebook or Twitter I post daily a feature I call Lean Tips.  It is meant to be advice, things I learned from experience, and some knowledge tidbits about Lean to […]

This past month A Lean Journey Blog turned 15 and as I look back on how I got started and who influenced my journey I wanted to revisit a previous series I started in 2012 called the Meet-up. One of the things I am so found of in the Lean community is the general wiliness […]

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on […]

Organizations that embrace the continuous improvement approach to business have many great tools and techniques from which to choose. Some organizations use them as part of a structured methodology like Lean, Six Sigma, or Toyota Kata. Others leverage them on their own. Every organization has unique needs and will need to adjust each method for […]

In the context of both Lean management and a professional networking site such as LinkedIn or on social media such as X, the discourse is filled with post after post telling top leaders that they must do this or they must do that to be better leaders. Like many others, I have done a lot […]

Wow, time flies! 15 years ago, Jamie Flinchbaugh and I embarked on our first-ever video podcast adventure as part of my Lean podcast (a podcast I started in 2006) Back then, my hair was much darker, and Jamie… well, let’s just say some things never change! 😂 Take a trip down memory lane with us […]

Nearly forty years ago, Toyota’s production system (TPS) was given a new generic name, “lean production.” Most people called it “lean manufacturing” owing to TPS’s manufacturing origin. The term “lean production” existed until about 2007 when there became a broader realization that Lean principles and practices apply to the work in all parts of a […]

One of great failures of Lean community leadership (pick any prominent name you like) is to give credit where credit is due. Shingijutsu, co-founded by Yoshiki Iwata and Chihiro Nakao, has the best track record of any consultancy since Shingijutsu was established in 1987. The article below tells one such story of success at Porsche. […]

  In this episode of People Solve Problems, host Jamie Flinchbaugh welcomes Lee Moore, Director of Foundry and Fab Materials at Qorvo. With nearly 25 years at Qorvo, Lee is deeply committed to developing a culture of proactive problem solvers within the organization. His role not only involves negotiating capacities and prices with external foundries […]

I was talking recently with a trusted friend in the Lean community. He told me a story. It’s certainly believable, even if it’s second or third-hand to me. He had no reason to make up a story like this. A relative of his works in a U.S. factory. Yes, we still have factories here. I’ll […]

Scroll down for how to subscribe, transcript, and more 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 […]

On Forbes: When The Big Picture Can Be Counterproductive Sometimes, the big picture can be overwhelming. When it is, it leads to doubt, delay, overthinking and other counterproductive behaviors. Roman emperor and Stoic philosopher Marcus Aurelius, who we could call Marcus the Practical, offers some helpful advice in this regard: “Remember—your responsibilities can be broken […]

The Bayerische Motoren Werke AG, or short BMW, is a maker of luxury vehicles, sport cars, and motorcycles. As part of my Grand Tour of German Automotive I visited their plants in Munich and Leipzig, and was quite impressed. In my view, it these are the best-performing automotive plants in Germany, and close to the […]