Learn why problem escalation processes send signals to frontline associates that they are not qualified to solve problems over work that they are best suited to solve. This elitist approach demoralizes and demotivates employees when their engagement opportunities are stripped away from leaders who do not walk the talk when they preach that problems need to be solved at the lowest possible level in the organization.
Apr 01, 2024•12 min•Ep. 32
Hida Oba discusses the importance of Standard Work and why all other aspects of Lean are connected to this very important, however, neglected component of the Toyota Production System. Hide also discusses how his famed father, Hajime Oba, facilitated the teachings of TPS Basics in his own unique way.
Mar 15, 2024•1 hr 27 min•Ep. 31
Hajime Oba had a storied career with Toyota, culminating as the CEO of the famed Toyota Supplier Support Center (TSSC) in Georgetown, KY. In this rare interview with his son, Hide Oba talks of the lessons learned from his father’s unique view which he perfected in the implementation of the Toyota Production System.
Mar 01, 2024•49 min•Ep. 30
More and more companies today are on the Lean bandwagon. There are plenty of Gemba Boards, fancy posters, Lean polo shirts, and don’t forget the yellow tape. But when asked about their Kaizen activity, the response is lethargic, at best. Learn how a rigorous and disciplined Kaizen approach is essential to any Lean transformation.
Feb 15, 2024•15 min•Ep. 29
The Production Preparation Process (3P) was invented by Chihiro Nakao, who is known as the Father of Moonshine (FOM). Nakao, one of the original disciples of Taiichi Ohno, (Father of the Toyota Production System) taught us at Danaher and GE how to develop processes that will drive your company to industry-wide competitive advantage. Learn from Jon Boucher, a star pupil and disciple of Nakao, how 3P and Moonshine are that part of Lean that few will ever learn, and why your company should adopt th...
Feb 01, 2024•1 hr 2 min•Ep. 28
All good humor has some truth to it. Please see Mark’s parody on how to get rid of GAN (Japanese for Cancer) from your organization with our new product GAN-AWAY! Just one spray and GAN is removed forever! GAN comes in many forms, including new consulting inventions that pull your attention away from the basics of Lean. Therefore, the title, “Basic” Lean Humor. Enjoy!
Jan 15, 2024•9 min•Ep. 27
Joe Rutz, Managing Director of Lean Horizons Consulting, was instrumental in the development of the Danaher Business System (DBS). Joe brought his experience in information technologies and administration to bring DBS to the next level. Learn from Joe his principles and guidelines as to when to apply information technology to an administrative process and when to not! Better yet, learn that IT solutions need to work for you, rather than the other way around!
Jan 01, 2024•43 min•Ep. 26
Learn what it takes to be able to call your process a “process.” These 10 Rules of a Process outline the basic framework of a process and, when followed, greatly increase the probability of sustaining and subsequently improving your results. If you focus on the process, the results will follow!
Dec 15, 2023•52 min•Ep. 25
An industry has been created where self-anointed, higher-power “Lean” organizations have convinced companies that their mark of approval is a necessary credential for Lean success. In our opinion, these organizations are shams whose real intent is to generate profits from consulting services, conferences, and publications. Learn why we feel the only mark of approval that matters is from your key stakeholders: Employees, Customers, and Shareholders.
Dec 01, 2023•18 min•Ep. 24
How many times have you attempted to solve a problem and were told you “CAN’T” do something because of customer requirements, specifications, government regulations, supplier guidelines, industry standards, etc.? The list goes on and on. In this episode, learn that these so-called regulations need to be challenged and, many times, are no longer in effect. Your problem-solving efforts will be substandard if you do not challenge the status quo. As Ronald Reagan once said, “Trust but verify!”...
Nov 15, 2023•30 min•Ep. 23
Problems can be categorized into three main types. It is helpful to understand whether you have a Type 0, Type 1, or Type 2 problem, since different courses of action may be required for each. Learn the three types of problems and why it is useful to understand the nature of the problem you are trying to solve, before embarking on your problem-solving journey.
Nov 01, 2023•22 min•Ep. 22
Most businesses today focus on lagging indicators, while important, are not conducive to proper problem-solving. Learn the difference between leading and lagging indicators and why it is essential to identify and improve the leading indicators if true improvement is to occur.
Oct 15, 2023•15 min•Ep. 21
Poor problem-solving usually begins with a poorly defined problem. When this happens there are usually many solutions looking for a problem. Listen to Mark DeLuzio describe the basics of creating a meaningful problem statement as well as the pitfalls surrounding problem definition.
Oct 01, 2023•14 min•Ep. 20
How many “solutions” proposed by leadership actually work? Do we really engage the front-line associates in solving problems? As a part of a series on Problem Solving, Mark DeLuzio discusses why it is crucial to engage those closest to the problem in developing a problem-solving culture. He also gives examples as to why this approach really works, and is a key ingredient towards enriching the work life of your fellow associates.
Sep 15, 2023•23 min•Ep. 19
Are you truly “solving” problems in your Lean Transformation, or simply reacting to problems and putting out today’s fire (problem “fixing”)? Listen to Mark DeLuzio talk about the difference and why it is critical to develop a true problem-solving culture within your organization.
Sep 01, 2023•22 min•Ep. 18
Mark DeLuzio discusses the topic of daily management and Gemba Walks in this episode of the Lean 911 Podcast. He highlights the confusion surrounding daily management and emphasizes the importance of using leading indicators rather than lagging indicators on Gemba boards. Mark also emphasizes the need to tie together the hard tools and soft tools of Lean, such as work standards and problem-solving, in order to truly advance in daily management. He encourages listeners to avoid "Fake Lean" and vi...
Aug 15, 2023•16 min•Ep. 17
Mark DeLuzio dives into the details of what constitutes a Kaizen and how it can be effectively communicated through a Kaizen report out. With a focus on providing insights into the process, Mark shares a presentation he has put together that outlines the various elements of a successful Kaizen.
Aug 01, 2023•20 min•Ep. 16
In this episode of Lean 9 1 1, Mark DeLuzio discusses the pitfalls of Kaizen, the second part of a three-part series on the subject. He highlights the importance of avoiding these pitfalls, whether you are new to Kaizen or have experience in its implementation. The first pitfall he addresses is the presence of observers in the Kaizen event. Mark firmly believes that there should be no observers and that everyone should be actively involved in the team. He emphasizes the value of learning by doin...
Jul 15, 2023•18 min•Ep. 15
Join Mark DeLuzio as he unravels the essence of Kaizen and presents the 10 Rules of Kaizen. Drawing from his extensive experience and learnings from notable figures in the industry, Mark shares practical wisdom that challenges conventional thinking and encourages continuous improvement. From discarding traditional concepts and keeping an open mind to rejecting excuses and embracing imperfection, these rules shed light on the fundamental principles behind successful Kaizen implementation. Mark al...
Jul 01, 2023•14 min•Ep. 14
In this podcast episode, Mark DeLuzio discusses the traditional definition of value-adding and non-value-adding activities in lean manufacturing. He argues that this definition is flawed because it does not consider the importance of all the activities that contribute to the success of a company, even if they are not directly related to the production process. He also points out that even activities that are traditionally considered to be value-adding can have non-value-adding aspects. DeLuzio c...
Jun 15, 2023•10 min•Ep. 13
This episode discusses the concept of accounting for lean, which is the modification of accounting processes and internal management reporting to better promote lean behaviors. Lean accounting is designed to take waste out of the accounting process, provide more timely and quality information, and help the accounting group become navigators rather than historians. Accounting for lean is important as it sets the foundation for other lean behaviors.
Jun 01, 2023•51 min•Ep. 12
Lean accounting is the application of lean concepts and methodologies to drive waste out of the accounting process, just like any other process. Accounting for Lean is modifying the accounting process and internal management reporting to promote lean behaviors and provide more timely, accurate, and customer-focused information. The benefits of lean accounting include eliminating waste, providing more timely and accurate information, freeing up accounting resources, and allowing accountants to be...
May 15, 2023•22 min•Ep. 11
Mark DeLuzio discusses his encounter with Dr. Joseph M. Juran.
May 01, 2023•21 min•Ep. 10
I am old enough to remember when McDonald's restaurants were scarce. Where I grew up in Central Connecticut, I could recall only one McDonald's franchise located just 10 miles away from our home. My Father took us there about twice a year, and when he did, I felt as if I had died and gone to heaven. McDonald's hamburgers were the finest thing I have ever tasted. Eating one today brings back those memories of the spiritual bliss I experienced in the back seat of my Father's turquoise, wood-panele...
Apr 15, 2023•26 min•Ep. 9
Capital Equipment Expenditures need to be vetted through more than a financial lens. In this podcast, Mark DeLuzio looks at CapEx from a Lean perspective and tells you how to avoid the pitfalls in making the wrong purchase decisions.
Mar 15, 2023•23 min•Ep. 8
Mark DeLuzio takes a look at the world's greatest "Speed Cuber," Max Park, and analyzes the qualities that Max displays, which makes him the world's greatest. Companies that wish to achieve world-class status would do themselves a favor if they simply observed Max Park, as there are many parallels worth noting.
Mar 01, 2023•14 min•Ep. 7
TAKT time is a key element of Standard Work. Every business has some semblance of a TAKT time, and it is important to understand what it is and how it applies to your business. In this episode, we'll clear up many of the misconceptions of TAKT Time, and why it is a key element of your lean transformation.
Feb 15, 2023•19 min•Ep. 6
The lean community has been talking a lot about trust and how it ties to the concept of Respect for People. In this episode, you'll discover the benefits and the role of trust in your lean transformation and why your success depends on it.
Feb 08, 2023•21 min•Ep. 5
While the Danaher Business System (DBS) started off as a copy of the Toyota Production System, it quickly became augmented to address Danaher's enterprise transformation, where all stakeholders win. In this episode, you'll learn some of the history behind the Danaher Business System and its differences and similarities with the Toyota Production System.
Jan 13, 2023•21 min•Ep. 4
Kanban is a method of communicating within a factory. It's how you ask for inventory when it's needed. Think about Kanban like a supermarket - when the shelves are empty, it is an indication that the product needs to be restocked. In this episode, we'll discuss how the concept of Kanban came about and how to implement it. Also, learn why Kanban is an admission of failure to do one-piece flow.
Jan 13, 2023•52 min•Ep. 3
