Scroll down for how to subscribe, transcript, and more My guest for Episode #503 of the Lean Blog Interviews Podcast is Sam Morgan of Illuminate Coaching + Consulting. He was previously a guest in Episode #457. Today’s episode was originally live-streamed on April 9th… Sam’s been doing a livestream series on “Lean Coaching for Lean […]

Good communication is a core leadership function and a key characteristic of a good leader. Effective communication and effective leadership are closely intertwined. As a leader, you need to be a skilled communicator in countless relationships at the organizational level, in communities and groups, and sometimes on a global scale in order to achieve results […]

When plotting a sequence of points, should we connect the dots into a line? We usually do, but it shouldn’t be a foregone conclusion. Every chart element should have a clear and precise meaning: if we can’t explain what it means or it is ambiguous, it confuses readers and we should omit it. The bulk […]

In my previous post on the automotive assembly line I showed how the earliest chain-driven assembly lines evolved to modern moving platforms. However, in automotive assembly, you also need to work underneath the car. While I have seen truck assembly lines where the entire undercarriage is flipped on its back, in automotive, this is usually […]

Some context: Measured in chapters (not time, alas) I’ve reached the halfway mark in the writing of my fifth book, Wholehearted: Engaging with Complexity in the Deliberately Adaptive Organisation, completing the first three of six chapters and with those, part I (Business agility at every scale) of two parts. I’ve adapted the article below from […]

tl;dr summary: Starbucks’ mobile order system demonstrates significant variability both in the organization of pickup areas and in how beverages like the Nitro Cold Brew are handled across different locations. Inconsistencies persist, such as different labeling methods and the timing of Nitro Cold Brew preparation, which varies with some stores waiting for customer presence to […]

How often do you hear executives blaming employees, including frontline workers, for different problems or poor performance? I don’t think that’s a good look when leaders do that. Leaders are responsible for the system. Even though they are part of a system, they have more freedom and more ability to change systems that ultimately drive […]

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 […]

The shift towards Industry 4.0 and smart manufacturing represents a significant evolution in how goods are produced, utilizing advanced technologies to enhance efficiency, productivity, and flexibility across various industries. Industry 4.0 refers to the fourth industrial revolution, characterized by integrating digital technologies into manufacturing processes, often termed “smart manufacturing.” This post will explore the ongoing […]

Digital transformation at the enterprise level is essential for organizations to remain competitive, relevant, and resilient in today’s rapidly evolving business landscape. By embracing digital technologies and modernizing processes, enterprises can enhance operational efficiency, improve agility, and unlock new opportunities for growth and innovation.  Digital innovation in business enables organizations to better understand and anticipate […]

In the blog post “Lean Zombies,” I said: The problem is akin to walking along a Möbius strip. Following a straight path leads management innovators in a loop, but also flips them around. The change in orientation gives them a feeling of progress — an illusion of progress within the confines of one’s own generation […]

The adoption of a continuous improvement culture has become increasingly important for organizations looking to achieve operational excellence and remain competitive. But what exactly is a continuous improvement culture, and why is it so pivotal for the success of modern enterprises? At its core, CIC is an organizational ethos that encourages constant evaluation, improvement ideas […]

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 Whose Chatbot is it anyway? In a March mixtape, […]

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 […]

In today’s fast-paced environment, Lean transformation emerges as a strategic approach to streamline processes, optimize resources, and drive continuous improvement while embracing technologies. Combining Lean methodology principles with innovation, Lean transformation emphasizes efficiency, agility, and customer-centricity.  Maximizing return on investment (ROI) in transformation is paramount as organizations seek to justify investments, prioritize initiatives, and ensure […]

Nearly 30 years ago, the sages of Lean decided to invert the focus of Toyota’s production system (TPS) from waste (and cost reduction) to value. That might not have been a mistake then, but it surely is a mistake now. And therefore, it is time to return to the original view of TPS: customer first […]

Transformation in healthcare involves integrating technology to improve patient care, streamline administrative processes, and enhance overall efficiency within the healthcare system.  Operational decisions are crucial in healthcare by determining resource allocation, staffing levels, and workflow management, ultimately improving patient outcomes and organizational performance. Leveraging tools allows healthcare providers to make informed operational decisions, leading to […]

A system without a goal is like a marathon without a finish line. But a system with a bad goal will result in a bad outcome. Traditional goal-setting methods use the SMART framework. Specific. Your goal should be well defined, clear, and unambiguous. Measurable. You can easily measure your progress towards the accomplishment of the goal. Achievable. The […]

I’m really excited to host and moderate the latest webinar in the KaiNexus Continuous Improvement Webinar series, which will be presented by my friend Elizabeth Chase from the City of Frisco, Texas. Elizabeth is a librarian and Material Services Manager for the city’s public library. I’ve had a chance to visit with her in their […]

Two years ago, I got rid of my extensive collection of Lean books. I donated them all to charity, some 75 books. But I did keep the books about Toyota, Toyota Production System, and important related works, most of which were published in the 1980s and 1990s. These are priceless original sources of the thinking, […]

tl;dr summary: This post examines the trend of Tommy John surgeries in MLB and MiLB using Process Behavior Charts, revealing that the perceived surge in injuries is within historical variation. The data suggests shifts in patterns rather than a sudden increase, emphasizing the importance of contextual data analysis. Is there a “spike” or a “rash” […]

If you’re just doing your job the best you can, then this article may not be for you. However, if you have multiple things going at once, from side hustles to learning projects, then what follows can be tremendously useful. For me, it is now an annual reflection and planning activity. You likely say yes […]

Automotive assembly is one of the pinnacles of modern manufacturing, having a very complex product of 30 000 parts as well as mass production in large quantities. The modern automotive moving assembly line is hence one of the most complex manufacturing operations in the world. In this two-post series I will look at how this […]

By Pascal Dennis (bio) By walking, I found out where I was going Irving Layton Acting your way to new thinking is easier than the other way round. (Tip of the hat to my colleague Mike Rother.) That’s why Politeness is called the door to the Great Virtues – (another tip of the hat, this […]

Communication is an essential part of our lives, and it’s something we do all day, every day. However, have you ever found yourself in a conversation where you feel like the other person isn’t really listening? Or have you ever been so focused on what you want to say that you’re not paying attention to […]

Transform Your World through the Power of Continuous Learning Want to know the secret to success? It’s about embracing lifelong learning, being willing to try new things and seek out information, setting intentions to get better, and embracing the failures that come with learning your way forward. I believe when we stay in learning – […]

I have been really enjoying this book, released in 2021, by Kiyoshi “Nate” Furuta, a retired Toyota executive: Welcome Problems, Find Success: Creating Toyota Cultures Around the World. I bought it a year ago and wish I had started reading it sooner! Furuta is the retired former chair and CEO of Toyota Boshoku America, Inc. […]

In a recent blog post titled “Lean Zombies,” there was a conversation on LinkedIn that should be of interest to everyone in the Lean community. The text accompanying the LinkedIn post read: “By now, almost everyone realizes that Lean has been reduced to a small suite of popular tools that have been absorbed into classical […]

After making many millions of dollars leading you down the Lean tools path, tricking you into thinking that Lean tools would make your company Lean, you now have the opportunity to spend $1500 per person to take a course where you will “learn why your lean effort is failing, and what to do differently.” For […]

We are often asked if continuous improvement and operational excellence are the same. They are not, but they are closely related. Continuous improvement involves constantly improving your business processes to reduce waste, cut costs, improve quality, and maximize human potential. It focuses on making each existing process perfect. Operational excellence goes further. It involves setting […]

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 […]

The Plan-Do-Check-Act (PDCA) cycle is a timeless and iterative management method used by businesses and organizations to foster continuous improvement in their operations. What’s more, it encourages a meticulous approach to problem-solving and process improvement, allowing teams to experiment with solutions on a manageable scale before full-scale implementation. In this blog, we’ll discuss the PDCA […]

Learn and appreciate the pioneering work of Masaaki Imai and the Kaizen Institute, and Yoshiki Iwata, Chihiro Nakao, Akiro Takenaka and Shingijutsu for bringing kaizen to the world. Please carefully study these 39 pages and return to the basics: TPS and kaizen! Learn more about the Kaizen Institute, Shingijutsu Global, and Shingijutsu USA. Kaizen-Institute-Part4Download NOTE: […]

  Cheryl Stokes, the CEO of CNEXT, joined Jamie Flinchbaugh on his podcast “People Solve Problems” to share her insights into corporate education, leadership development, culture change, diversity, equity, inclusion, and belonging. With a rich background that spans over two decades, Cheryl has significantly contributed to these fields through her roles at Heidrick & Struggles […]