Gemba Academy Podcast: Lean Manufacturing | Lean Office | Six Sigma | Toyota Kata | Productivity | Leadership

This week's guest is Peter Christian. Ron and Peter talk all about why Lean & Six Sigma programs often fail. They also explain what you can do to prevent some of these pitfalls. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Peter (2:53) Peter's background (3:32) Why continuous improvement programs fail (6:41) The balance between relying on external and internal sources (17:19) Ron's advice to Six Sigma Belt candidates (24:05) Peter's final words of wisdom (25:23) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Peter on LinkedIn Peter's Website Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTunes account and smartphone. The easiest way for iPhone users to listen to the show is via the free, and incr

This week's guest is Lee Houghton. Lee shared one of the most personal, moving stories we've had on this podcast. This one will stay with you for quite a while. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Lee (3:26) Lee's background (4:24) What Lee asked for from his best friend (9:57) The first lesson (10:54) The second lesson (12:03) The third lesson (13:57) A recap of the three lessons (15:26) Reflecting on hard questions (19:22) About Lee's podcast (22:46) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Lee on LinkedIn Lee's Website Lee's Podcast Ron's Episode on Lee's Podcast GA 351 | The Biggest Truth and Lie in Life with Lili Boyanova Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to yo

This week's guest is David Larsen. Ron and David had a great discussion about continuous improvement in both manufacturing and in healthcare. David also shared an interesting case study he worked on to improve employee safety. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires David (3:28) David's background (6:31) About David's case study (11:38) What motivated David (13:26) The highlights of the case study (15:42) How they simulated the Bolling mill procedure (18:32) What they learned from having written versus video standard works (21:02) Some of the cultural differences David has experienced (23:21) Their new onboarding process (25:49) What advice David would give his past self (27:29) What David is grateful for (30:46) David's final words of wisdom (34:40) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com David on LinkedIn David on iSixSigma

This week's guest is Luciana Toda. Ron and Luciana discussed the concept of entropy and its role in a culture of continuous improvement. They also explored how sustainability factors in as far as creating real, lasting change. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quotes that inspire Luciana (2:44) Luciana's background (7:09) What entropy is and how it relates to lean (9:30) Examples of how to start (12:29) Mistakes that make sustainability more difficult (19:27) The infinite games concept (21:42) The potential pitfalls (25:55) Luciana's final words of wisdom (33:49) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Luciana on LinkedIn Leading Change The Flow System The Infinite Game Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes w

This week's guest is Brandon Bartel. Ron and Brandon discussed setting intentions and the role intention plays. Brandon also shared his aspirations to incorporate more Toyota Kata into his lean journey. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Brandon (2:33) Brandon's background (3:11) What Respect for People means to Brandon (6:21) Defining intention (7:46) The role intention plays (10:55) Examples of getting it right and wrong (15:41) Brandon's advice (17:21) The best advice Brandon has ever received (20:48) What Brandon would say to his younger self (18:58) A skill Brandon wants to improve (21:54) Brandon's final words of wisdom (26:23) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Brandon on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. O

This week's guest is Adam Lawrence. Ron and Adam discussed Adam's new book, "The Wheel of Sustainability," including how and why he wrote it. Adam also shared some very moving stories that highlight the true power of lean. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Adam (5:53) Adam's background (7:08) About the Wheel of Sustainability (8:35) Why Adam wrote the book (9:41) The process of writing the book (10:57) A story about pink tools (14:15) A story about solving an employee's literal pain (23:35) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com GA 287 | The Wheel of Sustainability GA 303 | Running a Successful Kaizen Event GA 330 | The Power of 3P Adam on LinkedIn Adam on YouTube Process Improvement Partners on LinkedIn Process Improvement Partners Website The Wheel of Sustainability Virtual Book Launch Party The Wheel of Sustainabi

This week's guests are Thomas Lencki and Dagmar Vlahos. They explained all the powerful ways they use lean in higher education in New Hampshire. Thomas and Dagmar also touched on increasing engagement, navigating Covid-era challenges, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quotes that inspire them (3:47) Their backgrounds (5:57) Lean in higher education in New Hampshire (12:02) How lean is being applied (18:40) How Covid-19 has changed lean in higher education (23:59) Keeping engagement high (30:49) What a perfect day looks like (40:08) Their final words of wisdom (48:32) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com GA 251 | Lean in New Hampshire GA 354 | Avoiding the Continuous Appearance Trap Thomas on LinkedIn Dagmar on LinkedIn UNHLean on Twitter UNHLean Website Mentimeter Miro Subscribe & Never Miss New Episodes! Click to Subscrib

This week's guest is Dr. Jeffrey Liker. Jeff explained why he released a second edition of his bestselling book, The Toyota Way. Jeff and Ron also discussed scientific thinking and its relationship to other lean tools like 5S, Hoshin Kanri, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  Jeff's background (4:17) Why Jeff wrote the second edition (12:59) The structure of the 4P model (18:54) Whether or not you should start with the first edition (23:07) Why Japanese culture lends itself to scientific thinking (24:37) Learning scientific thinking (27:34) An anecdote about deliberate practice (33:19) The relationship between 5S and scientific thinking (39:09) Why Jeff added Hoshin Kanri to the second edition (45:30) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com The Toyota Way 2nd Edition Jeff on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in

This week's guest is Jason Haines. Ron and Jason discussed the importance of having a visual workplace, and how it, along with standard work, can actually help you retain employees. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Jason (2:38) Jason's background (3:14) The definition of standard work (5:12) How people are doing (6:34) How a lack of standard work leads to turnover (8:59) Jason's experience with TWI (10:15) Why you should start with standardization (14:16) A success story (15:54) Combating skepticism (20:07) Tying in other tools (22:29) About muri and mura (25:20) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Jason on LinkedIn Jason's Website Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downl

This week's guest is Prasad Akella. Prasad shared his take on the relationship between machine intelligence and human intelligence, and how they can work together in harmony. Prasad also stressed the importance of data and data literacy. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Prasad (2:06) Prasad's background (3:01) The relationship between humans and automation (7:13) How factories will look in ten years (10:52) The capabilities of today's machines (14:13) Why automation is not the only path to efficiency (16:30) Data literacy as a key skill for future generations (20:27) What Prasad is seeing as far as companies practicing lean (24:37) Prasad's final words of wisdom (30:30) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Prasad on LinkedIn Drishti Drishti on LinkedIn Drishti on Twitter Subscribe & Never Miss New Episodes! Click to Su

This week's guest is Patrick Adams. Patrick recently released a new book all about the concept of "continuous appearance." He explained what it can mean for your organization and its culture, and how it can be prevented. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Patrick (4:43) Patrick's background (5:22) Misconceptions about lean (7:39) About Patrick's new book Avoiding the Continuous Appearance Trap (9:33) Why companies are falling into the trap (14:20) How to prevent a culture of continuous appearance (16:39) The twelve questions that determine culture (21:05) More about question one (25:56) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Patrick's Website Patrick on LinkedIn Avoiding the Continuous Appearance Trap Avoiding the Continuous Appearance Trap on Amazon Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you e

This week's guest is Paul Bruno. Paul doesn't have a traditional lean background, but the fascinating research he shared on the story behind the creation of the Jeep is full of lean parallels and lessons. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  A quote that Paul likes (4:10) Paul's background and what he's up to these days (6:11) The army's Jeep procurement process (10:15) How long the process took (12:21) The quality of the first Jeep (15:10) About the Go Devil engine (17:47) The current and past states of Jeep (25:55) Paul's take on the Jeep journey overall (27:30) What we can learn from the Jeep story (29:45) About Paul's books (35:45) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com "The Original Jeeps" on Amazon Autographed Copies of "The Original Jeeps" "The Original Jeeps" Website "The Original Jeeps" Facebook Page Subscribe & Never Miss New Episodes!

This week we're sharing the audio of our recent Billy Taylor livestream. Billy is a lean powerhouse and his presentation is packed with practical and profound wisdom. If you're looking for some New Year's inspiration, this episode is for you. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  An anecdote about Muhammad Ali (1:01) What it takes to win (4:28) The importance of defining winning (11:48) What Billy discovered in Fayetteville (13:19) Exposing the hidden factory (15:46) Understanding the standard work (18:10) Establishing core values, principles, and standards (21:31) Flipping the pyramid (27:58) How the Fayetteville plant aligned winning (30:35) Executing winning (34:01) Inspiring trust (39:50) KPIs versus KPAs (45:23) Billy's closing thoughts (47:23) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Billy on LinkedIn Subscribe & Never Miss New Episodes! Click

This week's guest is Lili Boyanova. Lili shared some of what she's learned about lean so far and her vision for the future. Lili also asked Ron some pretty profound questions about life and lean. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Lili (5:13) Lili's background (6:28) Where Lili is with lean and what she's learned and validated (10:21) Lili's vision for her work (16:44) Collaborating with competitors (18:54) What Lili values in a leader (21:34) What has surprised Lili the most (22:58) The biggest truth in life (24:10) The biggest lie in life (27:22) What one tool Ron would use if he had to choose (30:23) Lili's final words of wisdom (36:41) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Lili on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes

This week's guest is Cristian Goyzueta. Cristian is relatively new to continuous improvement but had a wealth of knowledge to share. Cristian and Ron covered quite a few different topics, ranging from ISO to visual management and more.  A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Cristian (3:20) Cristian's background (4:44) ISO and lean in the service industry (8:30) Why it's hard to convince leaders to focus on the process (13:10) Cristian's goals (21:17) Experimenting with visual management (28:25) Cristian's final words of wisdom (33:36) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Cristian on LinkedIn The Toyota Way to Service Excellence Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTun

This week's guest is Richard Henderson. Richard has applied lean in various settings, and he shared some of what he's learned over the years. Richard also plays and coaches soccer, and he and Ron discussed how lean relates to sports. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Richard (2:31) Richard's background (4:04) His journey with lean (11:47) What he's looking forward to in regards to lean (16:58) Richard's success with lean (21:04) How he was able to experiment (25:47) Advice for those new to lean (29:39) Richard's thoughts on "specializing" in sports (31:38) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Richard on LinkedIn Richard's Website Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to y

This week's guest is Tejas Munot. Tejas shared what he learned during his time at VIBCO Vibrators, the importance of respect, and more. Tejas also interviewed Ron about HIS lean journey thus far. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Tejas (2:53) Tejas' background (3:56) The lean lessons he's learned (6:49) Asking versus requesting (8:50) A story about Karl, CEO of VIBCO Vibrators (9:51) The process for kaizen events (10:57) His camera strategy (14:49) What Ron wish he had known earlier in his career (17:12) What Ron learned from Jon Miller (21:22) A story about Ron's Master Black Belt (29:04) What the future of lean looks like (32:50) Teja's overall experience with lean (35:27) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com SimpliLean YouTube Tejas on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If y

This week's guest is Billy Taylor. Formerly the Director of Manufacturing at Goodyear, Billy has an impressive amount of lean knowledge. From the value of diversity, to performance maps, to deliberate practice, you won't want to miss this one. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  Billy's favorite quote (4:01) Billy's background (4:39) A story about the Fayetteville plant (9:30) Why Billy decided to start LinkedXL (12:11) What makes LinkedXL's approach different (14:48) The gap Billy has identified (17:09) Billy's advice for lower level lean practitioners (20:15) Key methods for creating performance maps (24:23) The value of diversity (26:18) Measuring non-quantifiable attributes (29:55) How the team ran the live stream using deliberate practice (33:47) Some examples of deliberate practice (37:54) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com GA 258 | Creat

This week's guest is Jay Hodge. Ron and Jay discussed the confusion around the word gemba and how gemba relates to kaizen. Jay has worked at GM, Toyota, and Caterpillar, to name a few, so he shared what it's like to make these transitions. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Jay (2:38) Jay's background (3:19) Confusion around the gemba (5:01) Examples of kaizen and gemba (6:17) What it was like being at Toyota (9:59) What it's like going to other companies (14:37) Effectively using tools to sustain improvements (18:57) Factors in creating a culture of excellence (21:47) The lean treasure chest (24:16) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Jay's Website The Lean Treasure Chest Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subsc

This week's guest is Adam Alamade. Adam works for a cochlear implant manufacturer and he described how they use continuous improvement. He and Ron also discussed dealing with resistance, owning problems, developing habits, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quotes that inspire Adam (3:01) Adam's background (5:47) What Adam is up to these days (8:17) Cochlear implants and hearing for the first time (10:13) The work Adam does (11:25) An example improvement (12:45) Building effective teams (14:38) Dealing with resistance (15:30) Taking ownership of problems (17:22) Developing brand new habits (19:17) What has surprised Adam (21:31) The tools they use (23:56) What Adam is most proud of (28:15) Adam's final words of wisdom (31:43) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Adam on LinkedIn Hearing for the First Time Video Subscribe & N