Interviews with lean thought leaders like Jim Womack and John Shook and those from of adjacent communities. The official podcast of the Lean Enterprise Institute.
Josh Howell, LEI President, Mark Reich, LEI Chief Engineer Strategy, and Art Smalley discuss the four basic types of problem-solving. Art is a well-known expert in leadership, management, and the Toyota Way. He worked at Toyota Motor Corp. in Japan; helped to transform Donnelly Corp. in Michigan; was a consultant with McKinsey & Co.; and has authored several award-winning books, including Four Types of Problems. The trio set out to discuss how the framework of the four types of problems maps onto the lean management system explained in Mark's recent book about hoshin kanri, Managing on Purpose, as well as daily management in Toyota, leadership, culture, and other related topics. The systematic intersection of these topics is a complex subject beyond just the simpler notion of “tools.” Art and Mark share respective viewpoints from their time at Toyota in Japan and what made the system so unique while trying to connect the dots of four types of problems, hoshin kanri, and other areas. Josh kicks off the podcast by asking Art and Mark to examine in detail troubleshooting — the most frequent and possibly most misunderstood type of problem-solving. A good troubleshooting environment involves quickly attacking known problems with known solutions to get operations back to normal (i.e., how to mitigate issues that prevent achievement of near-term goals). They also review troubleshooting's relationship with the other types of problem-solving and the “flavors” of the types — gap from standard (how to prevent a problem from recurring by eliminating its underlying root causes), target condition (kaizen to elevate the standard), and open-ended (innovations and breakthrough thinking) — as well as the complex interaction of the four types with daily management and hoshin kanri. Learn more about a lean management system and the connection between problem-solving, daily management, and hoshin kanri: lean.org/LMP
In this episode of the WLEI Podcast, we speak with Sandrine Olivencia, author of Build to Sell: The Lean Secret to Crafting Irresistible Products, co-founder of Taktique Academy, and partner at Lean Sensei Partners. This is the second time Sandrine has joined us on the WLEI podcast, and in this particular conversation, we discuss why lean product and process development principles are crucial for entrepreneurs in today's rapidly shifting market demands. The conversation explores: How Sandrine found her way to lean and agile and how early work by lean product and process development thinkers Al Ward, Jim Morgan, Durward Sobek, and more have influenced her career trajectory; How to get started when it comes to building a product-led organization, in part by moving from “feature frenzy” to a focus on value-driven, performance-based product development; What startups should be thinking about if they want to make it past those very challenging first five years; Where leaders tend to stumble with lean product and process development in tech; What excites Sandrine most about the future and the kinds of products and companies that inspire her. Learn more about lean product and process development at https://www.lean.org/explore-lean/product-process-development/
Mark Reich, LEI Chief Engineer of Strategy, and Karen Gaudet, LEI Senior Coach, talk with Michael Duncan, President of Viwinco, about his efforts to establish a robust daily management system in the family-owned window and door company and connect it to the company's hoshin kanri process. Michael grew up in the company and, after rising into leadership, spearheaded the company's transformation, implementing lean principles and tools while developing people. This enabled the company to more efficiently manage its challenging business model of customized products, varying demand, short lead times, and no finished-goods inventory. Success via lean recently has been enhanced by developing an improved strategic planning process and supporting it with a daily management system that develops a regular cadence and structure to elevate problems to manage performance, including achievement of KPIs and progress made with strategic projects. Learn more about how LEI can help your organization.
In this episode of the WLEI Podcast, we speak with product leader and angel investor Phil Green about product-centered entrepreneurship and what it takes to truly create value for customers. Since 2020, Phil has been the senior advisor for B2B and technology at Harvard Innovation Labs. Before the i-lab, Phil spent over 30 years working at various startups as a CEO, COO, CTO, and a product manager. The conversation explores: Some of the most exciting products and services Phil has seen come out of Harvard's entrepreneurial community What it takes to create a solid MVP (minimum viable product) Why Phil teaches “minimum valuable process,” not just “MVP” The different types of challenges teams face in large, distributed organizations versus smaller startups when it comes to lean thinking How to focus on lean and agile principles rather than rituals to move fast while staying responsive to customers and market demands Learn more about lean thinking and practice at lean.org
Josh Howell, LEI president, explores the topic of daily management with Joe Seestadt, Director Lab Outreach for Bronson Healthcare and a faculty member and coach with LEI. Joe trained as an industrial engineer and worked in manufacturing, and has now spent some 18 years in healthcare. He was instrumental in developing the Cleveland Clinic's daily management system, which has been recognized across the industry. Joe is unique in that he is both a lean guide to others as well as an owner and user of a system and concepts that he's helping individuals grasp as they try to transform their own organizations. He describes the importance of daily management as having the ability to know every day if you are ahead or behind, having a mechanism to solve problems at a daily beat in any type of operation (healthcare, service, or manufacturing), and as a means to bring strategy/hoshin kanri to fruition.
Josh Howell, LEI president, talks with Dr. Sarah Womack, an eight-year veteran of Toyota and author of Toyota's Improvement Thinking from the Inside. Sarah discusses how her transformation and that of other individuals within Toyota collectively contributed to organizational improvements and high performance. Her Toyota experiences exponentially advanced her learning and today enable her to successfully impart lean values and mindsets to organizations that are very unlike Toyota. Learn more about lean thinking and practice at lean.org
In this episode of the WLEI Podcast, we speak with Steve Spear, a senior lecturer at MIT's Sloan School of Management, senior fellow at the Institute of Healthcare Improvement, and associated faculty member at Adriane Labs of the Harvard School of Public Health. Spear is also author of The High-Velocity Edge and Wiring the Winning Organization and principal of SeeToSolve. The conversation explores: Stellar examples of product development innovation (and the learning cultures that made these achievements possible) What Lean, Six Sigma, Agile, DevOps, and more schools of systems thinking and management all have in common What business and product leaders across hardware and software can learn from each other Key ideas and core principles you should take away from his latest book What kind of leadership Steve believes is needed now and what good leadership looks like in practice, given all of the organizational challenges companies face today
In this episode of WLEI Podcast, we welcome Amy Smith, Founding Director of MIT's D-Lab, an innovative university-based program in international development and a senior lecturer in Mechanical Engineering at MIT.
In this episode of WLEI Podcast, we welcome Cynthia E. Smith, Curator of Socially Responsible Design at Cooper Hewitt, Smithsonian Design Museum and author of Design for the Other 90%. Cynthia speaks about design as a catalyst for change and what it means, as she says, to be in “the collective work of building capacity and agency in communities across the world.”
This week The Management Brief presents a podcast with Josh Howell, LEI President, and Mark Reich, LEI Chief Engineer, Strategy. They discuss Mark's 30-plus years working with hoshin kanri — two decades at Toyota and then coaching executives while with LEI — and the impact that the strategic planning and execution process has had on Toyota and the many companies with which Mark has supported. You'll hear how hoshin kanri helped Toyota establish self-reliant North American operations, which required commitment from top leaders outside of Japan establishing a vision and engaging and developing management amid a period of rapid growth. Mark also describes how companies beyond Toyota — even those without historically strong management and a culture of problem-solving and collaboration — have been able to establish these corporate traits while they're defining strategic objectives and taking actions to achieve them. To learn more about hoshin kanri and how to deploy the process in your company, be sure to also read Mark's upcoming book, Managing on Purpose.
In this edition of The Management Brief, Mark Reich sits down with Isao Yoshino, a 40-year veteran of Toyota and a driving force behind the company's success with hoshin kanri. Yoshino shares the impact that hoshin kanri and A3 problem-solving has had on him professionally and personally. Key takeaways include: · Multiple roles over four decades at Toyota shaped Yoshino's management beliefs and career. · Yoshino discusses working directly with Mikio Sugiura, who was instrumental in developing Toyota's hoshin kanri process. · Hoshin kanri can positively impact a company as it has Toyota, notes Yoshino, but it's not without a few challenges. · Delivering bad news first and an earnest desire to learn from failures were commonplace for Yoshino and Toyota executives and fostered the improvement mindset that still thrives in the company today.
In this episode of the WLEI podcast, we sit down with Mark Dolsen, President of TRQSS, a seat belt manufacturer that supplies Toyota and other automakers in North America. Mark shares insights into TRQSS's lean journey and the critical role of frontline supervisors in driving continuous improvement. Key takeaways include: TRQSS has evolved its lean practices over decades, starting with the influence of Japanese coordinators and later adopting TWI principles. The company's "TPS for Team Leaders" program focuses on developing supervisors' capabilities in areas like flow, standardized work, and kaizen. TRQSS's quality management approach is rooted in the principle of "mizenboushi" — proactively maintaining process conditions to ensure good parts every time. Read more about how TRQSS applies mizenboushi in this paper. Mark's leadership philosophy emphasizes coaching, teaching, and empowering employees to make decisions and contribute to the company's lean culture.
In this edition of The Management Brief, Mark Reich sits down with Geoff Miller, CEO of Grand Rapids Chair, to discuss his company's lean transformation journey. Geoff shares how the adoption of hoshin kanri and A3 problem-solving has helped the company maintain strategic focus and build organizational capability. Geoff offers a candid reflection on his leadership transformation, underscoring the importance of perseverance and continuous learning, even in the face of significant disruption. Key takeaways include: Hoshin Kanri enabled Grand Rapids Chair to build stability in critical daily management measures like safety, quality, and reliability. The catchball process for cascading strategic goals fostered alignment and buy-in across the management team. A3 problem-solving empowered employees across departments to tackle large, complex challenges and drive meaningful change. Sustaining a lean transformation requires personal commitment from leadership to model the problem-solving mindset and tools. Developing human capability in problem-solving is essential for realizing the full benefits of lean.
In this edition of The Management Brief, LEI President Josh Howell sat down with Charlie Murphy, Senior Vice President at Turner Construction, to discuss the company's remarkable lean transformation journey. Charlie shares how the organization leveraged core lean principles and practices to drive a dramatic improvement in safety performance and build a culture of continuous improvement. Key takeaways include: Turner's safety performance improvement, from a recordable incident rate of 5 per 200,000-man hours down to under 1, driven by fact-based problem-solving and a rigorous management system. Building problem-solving capability and implementing hoshin kanri connected high-level priorities to daily problem-solving and operational improvements. The shift from "relentless" to "co-learning" safety incident reviews fostered a more collaborative, fact-based approach to addressing safety issues. Standardizing daily management systems and empowering middle managers were critical steps in scaling lean practices across Turner's 1,500 active projects. Subscribe to The Management Brief for free.
In the latest edition of the Design Brief, we sit down with Jay Hill, the Vice President of Advanced Technology at GE Healthcare, to discuss the company's approach to product development in the complex healthcare technology space. Jay offers insights into: GE Healthcare's deep engagement with clinicians at all stages of product development, from needs identification to prototype evaluation. The "lead program integrator" role and its importance in managing the integration of complex, multi-disciplinary healthcare systems. GE Healthcare's structured approach to monitoring technology trends and matching them with clinical problems to inform their product roadmap. Exciting applications of AI in healthcare, from automating workflows to supporting clinicians in making better diagnostic and treatment decisions. Advice for medical students and early-career clinicians on embracing the evolving relationship between their practice and advancing technologies.
In the latest issue of The Management Brief, host Mark Reich sits down with Marcia Brey, the Vice President of Logistics at GE Appliances. Marcia shares her extensive career journey at GE Appliances, spanning roles in design, customer service, distribution, quality, and eventually leading the company's lean enterprise transformation. Key points discussed include: Marcia's initial exposure to lean principles like value-stream mapping and kaizen events while leading the warehouse network. Her transition to plant manager of a complex refrigeration factory and the importance of daily management and engaging the team to solve problems. The creation of GE Appliances' lean enterprise team in 2016 to implement new processes and drive strategic alignment using hoshin kanri. How hoshin kanri is used to cascade objectives, enable cross-functional collaboration, and develop leadership skills through reflection. Marcia's advice for leaders struggling to implement strategy and daily management systems, emphasizing the need to start somewhere and continuously improve. Her current role in logistics and the opportunities to further explore customer problems and strengthen the value stream by breaking down traditional organizational boundaries.
In this episode of the WLEI Podcast, we're joined by Dr. Carlos Frederico Pinto (aka Dr. Fred), a medical oncologist with over 30 years of experience leading transformative changes in cancer care. Dr. Pinto shares insights on using lean thinking to dramatically improve patient outcomes and access to care. Some highlights from the conversation include: How redesigning patient pathways allowed breast cancer patients to receive all necessary tests and treatments in a single visit. Dr. Fred's current work with public healthcare institutions in Brazil reducing wait times for prostate cancer patients from over 1,000 days to less than two weeks. The importance of daily management and developing leaders with the right behaviors and values to drive lasting change. Dr. Fred's upcoming book, "The Systems Architect Manifesto," which shares his insights on organizational transformation.
In this episode of the WLEI Podcast, we sit down with Jose Ferro, the founder of the Lean Institute Brasil and co-author of LEI's new book Daily Management to Execute Strategy: Solving problems and developing people every day. José shares his insights on how companies can effectively connect their high-level strategy to frontline operations and the importance of developing a problem-solving culture. Some key takeaways from the conversation include: Daily management is a structured process to align an organization's strategy with its day-to-day work. Solving problems at the operational level is fundamental to an effective daily management system and developing people. Leader behavior can enable effective problem-solving and destroy effective problem-solving. A clearly defined help chain connects frontline daily management to managerial-level daily management and provides systematic support to frontline operations. The approach to implementing daily management should be tailored to each organization's specific needs and context. Order your copy of Daily Management to Execute Strategy: https://www.lean.org/store/book/daily-management-to-execute-strategy-solving-problems-and-developing-people-every-day/ Discounts up to 20% off are available for large orders.
In this episode of the WLEI podcast, we speak with Karen Khachikyan, CEO of Expper Technologies, and Mineh Badmagharian, the clinical and product development leader. They shared the remarkable story behind Robin, a robot designed to provide emotional support and comfort to pediatric and geriatric patients in hospitals and care facilities. What stood out most was the team's relentless focus on truly understanding their end users - the children, seniors, and medical staff who interact with Robin. Insights from the discussion include: The importance of understanding your customer. The team spent years carefully observing how children reacted to different iterations of Robin, refining details like the robot's age and favorite animal to create a personality kids would love. Integrating the technical and clinical needs. The two teams weren't always aligned, but they found creative solutions by keeping the user experience as the north star. Understanding the human element of robotics. - Perhaps most inspiring was the team's deep personal connection to Robin, treating it as a beloved member of the family, a sentiment shared by nurses and patients with access to a Robin. Before listening, check out videos of Robin in action. https://youtu.be/FwZuUkjoj4M https://youtube.com/shorts/fkBHxs2aUA4?si=mK2eKW_5lL8vyBw1
In this episode of the WLEI podcast, we explore the LPPD principle: Understand Before You Execute. Too often, companies commit to a product design before assessing their customers' needs, leading to development churn and failed products. The conversation examines how to avoid that trap by precisely identifying customer needs before development and features a case study of a company that did just that. However, people did not engage in this conversation. Artificial intelligence, specifically Google's NotebookLM, generated the entire discussion based only on this six-minute video clip. The result is astonishing. Tune in and share in the comments what you thought of the conversation.
In this episode of WLEI Podcast, we welcome Sandrine Olivencia, author of Build to Sell and expert in applying Lean principles to software development. Sandrine shares her journey from waterfall to Agile and eventually to Lean Product and Process Development (LPPD), which she sees as a more holistic and sustainable system for building great products and lasting businesses. The conversation explores: The importance of Gemba and why leaders at all levels need to stay closely connected to customers and the problems they face. How Lean thinking can help companies avoid “feature frenzy mode” and maintain a clear focus on delivering customer value. Why even mature tech companies often struggle to develop people and the steps leaders can take to build a culture of problem-solving and continuous improvement. Practical advice on where to start implementing Lean principles, including Sandrine's three key strategies for building a more product-led company. The limitations of so-called “founder mode” and “manager mode” and how an alternative “Lean management mode” addresses the shortcomings of both.
In this episode of the WLEI podcast, we speak with Regis Megina, a software industry veteran who has undergone a journey from Agile to Lean. Regis shares insights on: How he transitioned from early frustrations with waterfall development to embracing Agile and Extreme Programming The challenges he faced in spreading these new ideas, and why he ultimately sought a deeper understanding of Lean principles Regis' current work applying Lean Thinking to startups and scale-ups, including creating educational materials and training programs The importance of continuous learning, technical mastery, and developing team capabilities - rather than just focusing on process improvement tools. For more insights into Lean Thinking applied to product development, subscribe to the Design Brief newsletter.
In this episode of the WLEI podcast, LEI speaks with prolific author and business leader Art Byrne. During the discussion, Art shares his decades-long journey leading lean transformation, from running kaizen events with the first wave of ex-Toyota consultants in the US to leading manufacturer Wiremold to record profitability. For a decade, Art wrote 100 "Ask Art" columns, answering the lean community's most pressing questions. He has compiled the best of those into a new book, The Lean Turnaround Answer Book: 40 Years of Lean Observation. Our conversation covered: The transformative impact of implementing the Toyota Production System to improve efficiency, quality, and customer service. The critical role of leadership and involving top executives in driving successful lean transformations through setting stretch goals and fostering a culture of continuous improvement. The challenges of traditional accounting methods in a lean environment and the need to transition to lean accounting practices. The strategic advantages of reducing setup times and lead times in manufacturing, allowing companies to gain a competitive advantage. Practical insights from the author's experience writing a book to provide answers to common questions about implementing lean principles across various industries.
In this episode of the WLEI podcast, LEI speaks with software industry veteran Robert Martin. Robert is one of the original signers of the Agile Manifesto and the author of several influential books, including Clean Code: A Handbook of Agile Software Craftsmanship. During the conversation, Robert shared insightful perspectives on some of the biggest challenges facing software development today. From the demographic problem of perpetual inexperience to his pioneering approach to development dubbed "software craftsmanship" that aims to promote quality work, Robert covered a wide range of issues impacting the industry. Some other topics discussed include: Balancing speed and quality in development and emphasizing a quality-first mindset. The benefits of test-driven development, such as providing freedom to change code safely. AI's potential impacts and appropriate uses of AI-generated code. Be among the first to get the latest insights from LEI's Lean Product and Process Development (LPPD) thought leaders and practitioners. This podcast was delivered to subscribers of The Design Brief, LEI's newsletter devoted to improving organizations' innovation capability. It is the second of four in a series focused on craftsmanship or pursuing perfection in products and people. Craftsmanship embodies simple elegance, precise execution, and a deep, personal connection to work that transforms both the creation and the creator.
In this episode of the WLEI podcast, Jim Womack and John Krafcik share the origin story of the term "lean." Jim led the MIT global benchmarking study of the automotive industry, which led to the seminal book The Machine That Changed the World, and John was one of the principal researchers. Jim went on to co-author a similarly influential book, Lean Thinking, and founded the Lean Enterprise Institute. John Krafcik became an executive in the auto industry, serving as CEO of Hyundai America and Waymo. The discussion closes by turning from the past to the future with updates on Waymo's autonomous driving technology. This conversation took place at LEI's Lean Summit in March 2024. Special note: Are you keen to explore how technology such as autonomy will reshape the future workplace? Join us at "The Future of People at Work Symposium" July 18-19 in Detriot, MI, to learn about these challenges from business luminaries like Jim Womack and Jeff Liker and collaborate with peers to address them. Click here to learn more and register.
In this episode of the WLEI podcast, LEI speaks with Dr. Jackie Gerhart and Dr. Christopher Longhurst. Dr. Gerhart is a family physician and VP of clinical informatics at Epic Systems, while Dr. Longhurst is the Chief Medical Officer and Chief Digital Officer at UC San Diego Health. In the discussion, we explore: How health systems are using AI to improve patient outcomes. The potential for AI to reduce clinicians' cognitive burden, allowing them to reconnect with patients. What educators should consider when training the next generation of doctors who will begin their careers with access to AI. Special note: As this conversation demonstrates, the workplace is rapidly changing, fueled by technological advancements like AI, shifting generational expectations, and evolving customer demands. Join LEI at "The Future of People at Work Symposium" July 18-19 in Detriot, MI to learn about these challenges from business luminaries like Jim Womack and Jeff Liker and collaborate with peers to address them. Click here to learn more and register.
In this episode of the WLEI podcast, LEI speaks with Alan Goodman, professor and department chair of quality engineering at Milwaukee Area Technical College. Alan spent his career in operations at GE before becoming a professor. The podcast explores his recent work to teach young students lean skills to prepare them for careers after school. In the discussion, we explore: Alan's background in lean and how he's transferring his skills to students through a program he's grown from a one-week online course to a year-round initiative. Getting students interested in lean concepts through interactive games and how to apply these lessons to adult learning. Alan's vision to partner with companies to create a pipeline for students to enter the workforce from school. Methods Alan incorporates new technologies like AI and gamification into his teaching methods to foster creativity and critical thinking. If you'd like to support Alan's work, check out https://cityonahillmke.org.
In this episode of the WLEI podcast, we speak with Ben Armstrong, Executive Director of MIT's Industrial Performance Center, and Jim Morgan, Senior Advisor at the Lean Enterprise Institute. They share perspectives from Ben's extensive research on the history and future of US manufacturing and Jim's first-hand knowledge of developing new products and production processes. In our discussion, we explore: The rise and decline of America's manufacturing expertise and how the decoupling of design and production has impacted innovation. Challenges currently facing small and medium manufacturers, and what investments they should consider. The role of industrial policy and government support in spurring new growth in US manufacturing. Emerging technologies like AI and how they could transform manufacturing operations going forward. This podcast was delivered to subscribers of The Design Brief, LEI's newsletter devoted to improving organizations' innovation capability. It is the second of four in a series on process development entitled “Making Things Well.” Subscribe to the Design Brief newsletter by clicking here.
Electrification has given rise to new American automotive ventures such as Tesla, Rivian, and Lucid Motors. Aside from the powertrain, these companies are innovating the driving experience through breakthrough performance and by deeply integrating software into vehicle architecture. These disruptions demonstrate exciting possibilities but raise a challenge: how can companies innovate while upholding customer expectations of quality? In an episode of the WLEI podcast, LEI sat down with industry veteran and Lucid Motors' Vice President of Quality Jeri Ford to explore that question. Jeri has over 30 years of experience in the automotive industry, having held leadership roles at Ford and Rivian before joining Lucid. The conversation explores: How product development impacts quality downstream in manufacturing and supply chain. The importance of collaboration between functions to achieve quality objectives. Balancing speed and quality in bringing new vehicles to market. Adapting processes for the integration of software and hardware in modern vehicles. Building alignment and a culture of quality in a startup environment. Listen to gain these insights and learn about the challenges facing the automotive industry in an era of technological change. Be among the first to get the latest insights from LEI's Lean Product and Process Development (LPPD) thought leaders and practitioners. This article was delivered to subscribers of The Design Brief, LEI's newsletter devoted to improving organizations' innovation capability. It is the fourth of five in a series on quality entitled “Whatever Happened to Quality First? Rethinking Product Development the Wake of Recalls and Catastrophic Failures.” Click to read the first, second, and third articles.
In this episode of the WLEI podcast, LEI speaks with Emily Swaney and Alli Kulp from OhioHealth. Emily is the senior director of OhioHealth's lean promotion office, leading the organization's continuous improvement team. Alli is a senior advisor in the lean promotion office and previously worked as a registered nurse. In our discussion, we explore: The lean journey at OhioHealth since 2006 and their goal of creating a culture of 35,000 problem solvers. OhioHealth's strategic goal deployment process and how they cascade goals throughout such a large healthcare system. How lean daily management and problem solving are implemented at the frontlines through huddles and visual boards. Tools OhioHealth has developed to assess lean leadership behaviors and the management system to drive progress. Emily and Alli will lead a learning session on creating leadership assessment tools to foster development at the Lean Summit on March 19-20 in Carlsbad, CA.
In this episode of the WLEI podcast, we speak with Dennis Wade from Oakland University and Lisa Eshbach, PhD from Ferris State University. They share their universities' programs that provide hands-on lean learning experiences for students through collaboration with industry partners. In our discussion, we explore: The backgrounds and roles of Dennis Wade and Lisa Eshbach in academia and their work connecting students to real-world lean projects. The models used at Ferris State University and Oakland University for experiential learning projects, including course-based projects and paid internships. The impact of these programs on students' development of lean skills and tools, as well as skills like collaboration and problem-solving. Examples of projects undertaken by students, such as a kanban system for an eye clinic supply room and creating a food pickup process for a university food pantry. Dennis and Lisa will lead a learning session on connecting industry to academia at the Lean Summit on March 19-20 in Carlsbad, CA. To contribute to the James P. Womack Scholarship, which funds student internships at Oakland University, email us at info@lean.org. Click here to read case studies from past student projects funded by the scholarship.
In this episode of the WLEI Podcast, our guests are Jennifer Trask and Brittney Heatherington from MillerKnoll. Trask is the Director of the MillerKnoll Performance System (HMPS) for business processes and dealer network, while Heatherington is a continuous improvement coach for the dealer network. In our discussion, we explore: MillerKnoll's methodical approach to people development. How MillerKnoll has built a culture of operational excellence throughout its value stream from its factories to its dealers. How MillerKnoll successfully engages dealers in problem-solving by coaching at the gemba. The importance of approaching problems situationally versus applying a fixed solution.
In this episode of the WLEI podcast, LEI speaks with Billy Taylor, former operations executive at Goodyear Tire & Rubber Company. He is now President of LinkedXL and author of The Winning Link: a Proven Process to Define, Align, and Execute Strategy at Every Level. In our discussion, we explore: Billy's career journey from third shift supervisor to director of North American operations for Goodyear. How Billy led a transformation of one of Goodyear's worst-performing plants through instituting a few core principles: deliberate clarity, defined ownership, deliberate practice, and trust. Billy's approach to scaling a management system from a single plant to multiple plants across North America through intense collaboration with plant leaders. The current challenges of retaining employees due to changing workforce mindsets post-COVID and how to re-engage workers.
In this episode of the WLEI podcast, LEI's guests are Mary Nell Egan and Lisa Karam from MassMutual, a leading insurance company. Egan and Karam delve into the intricacies of transformation in a traditionally cautious, large organization. In our discussion, we explore several key themes: MassMutual's evolution from a tool-centric to a customer-value approach in their lean journey. The methods Egan and Karam used to engage previously disengaged leaders with lean, linking continuous improvement to corporate strategy. The critical role of meeting people where they are in mitigating resistance to change. The significance of resilience in lean transformation.
LEI chats with Frank Paluch, Retired President of Honda R&D Americas, and Lara Harrington, Retired Honda Chief Engineer. Frank and Lara share how Honda utilized Lean Product and Process Development principles to launch successful vehicles like the Honda Passport. During the conversation we dive into the following: Understanding Customer Value – As Chief Engineer of the Honda Passport Lara explains how she used rapid prototyping and gathered consumer feedback early in the development process to determine a vehicle design that would appeal to customers and grow Honda's market share. The Chief Engineer – Frank and Lara reflect on the chief engineer's role, what makes a great chief engineer, and the matrix organization in which they work. People Development – Comparing hiring in engineering talent versus developing it internally. Future of the Auto Industry – Discussing the industry push toward EVs and contrasting Tesla's approach to development to Toyota's. Special note: Lara and Frank will lead a keynote about Lean Product and Process Development at the Lean Summit in March 2024. To learn more and register, click here.
In this episode of the WLEI Podcast, we speak with Jill Katic and Grace Eovaldi from Barton Malow, a major construction company that has recently seen significant growth. Jill and Grace share how they've been working to foster a culture of problem solving throughout Barton Malow, principally through a program dubbed Lean University. During the conversation we dive into the following: Lean Principles and A3 Problem-Solving: Exploring Lean University's five-day training program, which introduces participants to lean principles and the A3 problem-solving method over a three-month period. Problem Identification and Analysis: How Jill and Grace use the program to help participants identify and dissect problems in their work, guiding them in developing effective countermeasures. Business and Cultural Results at Barton Mallow: Insights into the tangible business outcomes and cultural shifts experienced by Barton Malow since beginning Lean University. Lean Thinking and Problem-Solving Skills: The significance of Lean University for organizations seeking to cultivate lean thinking and problem-solving abilities among their employees. Barton Mallow's Lean Journey: An overview of Barton Malow's experience with Lean University and its role in transforming the company's culture. Special note: Jill and Grace will lead a learning session about building a problem-solving culture through Lean University at the Lean Summit in March 2024. To learn more and register, click here.
In this episode of the WLEI Podcast, we talk with Fabrice Bernhard and Catherine Chabiron. Fabrice is the co-founder of Theodo, a fast-growing software company, and Catherine is the author of the new book, Learning to Scale at Theodo: Growing a Fast and Resilient Company. Fabrice and Catherine share how Theodo has seamlessly integrated lean thinking into its management system enabling it to grow rapidly while maintaining a customer-first mindset and ship quality software. During the conversation, we dive into: Lean vs. Agile: How Theodo found lean thinking and how it complements agile, while challenging traditional perspectives in the software industry. Quality vs. Speed: Navigating the delicate balance between producing high-quality code and meeting the demands for rapid delivery. Customer Focus: How lean has enhanced Theodo's customer-centric approach, making it a hallmark of their operations. Learning Organizations: The role of continuous learning in building resilient teams that not only solve technical problems but contribute to organizational growth. People Development: How Theodo leverages problem-solving at the gemba to foster a culture of continuous improvement and employee development. Special note: During the conversation, we mention the book The Toyota Way of Dantotsu Radical Quality Improvement, which Theodo has been using to transform its approach to improving quality.
In this episode of the WLEI Podcast, we speak with Mehmet Gur, Senior Director of Operations Engineering at DHL eCommerce. He has been leading the company's next-generation automation efforts. Since the pandemic, DHL eCommerce – DHL's business-to-consumer unit – has faced dramatic increases in volume. This surge required new automation technology to meet customer demand and heightened expectations regarding delivery speed. Mehmet oversees a large team of technical engineers tasked with meeting this challenge. During the discussion we touch on: Lean Thinking and Automation: How Mehmet's team used value-stream mapping to close the gap between automation equipment's theoretical throughput and actual throughput. Automation Evaluation: What should organizations consider before investing millions in new technology. People Development: How to use problem-solving at the gemba to not just solve intractable technical problems but develop engineers. AI in Distribution: How emerging technologies are revolutionizing logistics for higher throughput and customer satisfaction. Mehmet will lead a learning session on these themes at the LEI Lean Summit in March 2024. To learn more and take advantage of early registration discounts, visit lean.org/summit. Register by October 31 to save up to $900 on your summit registration.
In this episode of the WLEI Podcast, we speak with Jay Multanen and Jared Ragozzine from Bestbath, a manufacturer specializing in showers and bathtubs for both commercial and residential buildings. Jay is the co-CEO, while Jared is Director of Lean and Continuous Improvement. During the conversation we touch on: Organizational Transformation: Gain insights into how Bestbath has built a problem-solving culture through methodical structural changes and targeted people development strategies. Competitive Differentiation: Understand how adopting lean practices has not only streamlined their operations but conferred a significant competitive edge in the market. Strengthening Partnerships: Learn how lean thinking has fortified Bestbath's relationships with their construction trade partners, thereby enhancing collaborative opportunities. Profit-Share Model: Explore Bestbath's innovative profit-sharing scheme that has been pivotal in fostering the right behaviors across all levels, from the C-suite to the shop floor. Jay and Jared will host a learning session on building a problem-solving culture at the Lean Summit on March 19-20, 2024. Register by October 31 to save up to $900 on your registration. Click here to learn more and register.
In the latest episode of the WLEI podcast, we delve into hoshin kanri (strategy deployment) with Otto Funke and Joseph Tamayo from GlobalFoundries, a global leader in semiconductor manufacturing. Otto has overseen the strategic planning process at one of GlobalFoundries' production facilities for sixteen years. He will share insights on how the site has developed a robust process that has withstood leadership changes. Alongside Joseph, they will explore how this process creates alignment around objectives, both vertically and horizontally, enabling front-line workers to link their tasks to broader corporate goals. Furthermore, they will shed light on how this strategic approach is instrumental in cultivating GlobalFoundries' next generation of leaders. Otto and Joseph will host a learning session on hoshin kanri at the Lean Summit on March 19-20 with optional workshops on March 21-22. Register by October 31 to save up to $900 on your registration. Click here to learn more and register.
In the latest episode of the WLEI podcast, we explore the topic of organizational change with Dr. Lynn Kelley, former vice president of supply chain and continuous improvement at Union Pacific Railroad and author of the new book Change Questions. Kelley posits that there is no such thing as a fixed plan for a successful transformation. Leaders must approach change situationally, recognizing they face unique challenges no single method could address. In her book, she proposes a series of questions that methodically guide management to implement change and measure its impact: What is your value-driven purpose? What is the work to be done to achieve the purpose or to solve the problem? How will you engage and develop employees? How will you establish a supportive management system with the appropriate leader behaviors? What are your organization's beliefs, values, norms, attitudes and assumptions? By grappling with these questions, leaders will be able to design and implement a lasting transformation that leads to better business outcomes and engaged employees. To learn more about the book and download a free digital workbook, check out www.changequestions.net
In the latest episode of the WLEI podcast, we take a deep dive into a new venture whose goal is to rekindle America's industrial tradition. Re:Build Manufacturing was founded by former Amazon executive Jeff Wilke in 2021. We sat down with its CEO Miles Arnone and Chief Lean officer Bonnie Davis to learn about Re:Build Manufacturing's purpose and how it fulfills it. For decades U.S. manufacturers swept up by the opportunity to maximize profits with low-cost labor have been offshoring manufacturing. But the short-term boost in profits has generated long-term, unintended consequences. Communities that once thrived on manufacturing experienced severe economic downturns. This decline led to increased economic inequality, as those who lost their jobs struggled to find employment that matched their skills and offered comparable wages. Also, manufacturers struggled to protect their innovations as overseas suppliers threatened intellectual property theft or infringement. And the offshoring trend has eroded America's manufacturing and engineering capabilities. As companies began to rely on overseas suppliers, they lost valuable knowledge and skills that were once a hallmark of American industry. During the podcast, Miles and Bonnie delve into the specifics of how Re:Build's strategy works, as well as the company's culture and mission. They provide valuable insights into the future of American manufacturing and the vital role that Re:Build aims to play in reshaping it.
While Lean can trace its direct roots to the production system launched by Toyota more than 50 years ago, its timeless appeal translates into immediate practical countermeasures in a surprising number of situations. What A Unicorn Knows, a terrific new book by authors Matt May and Pablo Dominguez, proves this by presenting a comprehensive application of lean principles that couldn't be more timely. Join us for their conversation with WLEI host Tom Ehrenfeld for a wide-ranging exploration of the deep relevance of lean for growing companies today.
What is the best way to tackle complex problems? Getting better at this perennial challenge certainly fuels the beating heart of lean practice. It is the key theme in author Paolo Savaget's new book, The Four Workarounds: Strategies from the World's Scrappiest Organizations for Tackling Complex Problems. He discusses his findings with WLEI host Tom Ehrenfeld.
Lean practice has always coexisted with technology that enables the human operators to do their job better—in the service of delivering more value with less waste to the customer. But do today's digitized, information-saturated, workplaces provide so much assistance that the machines actually get in the way? In his new book, Augmented Lean, co-author Natan Linder talks with WLEI host Tom Ehrenfeld about how Tulip, the company he co-founded to provide a “human-centric framework for managing frontline operations,” seeks to delegate technology and improvement to the operators doing the key lean work.
Lean veteran Billy Taylor, author of the new book The Winning Link: A Proven Process to Define, Align, and Execute Strategy at Every Level, discusses with WLEI Host Tom Ehrenfeld how to cultivate "extreme leadership" as a means of building a cohesive and top-tier organization. Bill shares a "connected operating system" that, he says, helps people and organizations define and achieve ambitious goals. He learned and developed this approach through decades of success at Goodyear Tire & Rubber Co.
Organizing a restaurant kitchen is a daunting task to think about. Find and establish the problems at hand, implement an improved process to adhere to those problems. It all lends itself towards increased profitability, more respect for the workers with emphasis on value-creating work, increased tact-time; but its also much easier said than done. A flagship restaurant worked with LEI coaches and learned to increase their profitability through the lens of storytelling, where each piece is an innate - and respected - part of the whole. Listen in to hear how this all came together, and also check out the case study complementing this podcast.
Regret, the pervasive and often toxic emotional mess most of us invariably experience, need not be so painful, says best-selling author Dan Pink. In fact, his new book The Power of Regret counsels readers to deliberately view regret as a process that can be examined in a way to help us all lead better lives. This WLEI podcast with host Tom Ehrenfeld explores how Pink came to this conclusion and explores parallels between his approach to processing regret and Lean's mindful approach to framing problems for continuous improvement.
In 2021 Toyota Motor became the first manufacturer from outside the United States to sell the most cars in the USA. While this news hook may very well prove to be transient, it raises key issues about what has accounted for the company's success. What aspects of Toyota's vaunted production system, which is foundational for lean, have supported its success? How does Toyota's approach contrast with a company such as Tesla? How can companies productively balance the need to develop products that dazzle consumers with the need to simultaneously develop the brilliant processes that produce these coveted items? Join LEI founder Jim Womack and LEI President Josh Howell in a conversation hosted by Tom Ehrenfeld about lean's enduring value in today's time of discontinuity.
In this episode of the WLEI Podcast, Matt Savas sits down with LEI President Josh Howell and Richard Vellante, Executive Director of Community and Training Events at LEI. They discuss the labor shortage and recent supply chain issues with the perspectives and intuition, as well as addressing recent blames towards lean within the supply chain industry. Leadership is at the center of these topics, with Rich's experience as an Executive Chef lending some hands on nuance to the conversation. Leaders should be hard on the process, not the people getting accustomed to that process. NFT's are also discussed, as their ever developing trajectory in the media landscape surely can borrow a thing or two from the way that lean thinkers lead and act.
How much of your work time do you spend doing actual work that leverages what you do best? And how much of your invaluable time and focus is chipped away by myriad distractions—of which the most pernicious might be email and its constant demand for your attention. I'm Tom Ehrenfeld, host of the Lean Enterprise Institute's WLEI podcast. I spoke with author Cal Newport about his newest book, A World Without Email, where he challenges us to rethink why we need to be constantly plugged into communication that seldom helps us produce valuable work.
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