Lean 911

Replay from our live April 7 webinar. Most Lean initiatives stall because leaders chase tools instead of building capability. In this rare unfiltered session, Mark DeLuzio teams up with seasoned transformation veteran Mark Forkun for a blunt conversation on the realities of Lean, why most organizations fake it, and what it takes to get results that last. From the hidden failure of matrix org chart...

In this episode, Mark DeLuzio talks about Lean Horizons' Managing Director Jon Boucher discussing the span of control necessary for problem-solving. In particular, Mark and Jon address the following: What is span of control, and why is it important for any lean journey Problem Solving – What is the definition of a problem? What is meant by standards? How do you begin, how deep do you go, and what...

In this episode, Mark DeLuzio talks about why Lean/CI people are not being listened to and gives sage advice as to how to reverse this trend.

Do you want to get the attention of leadership? Then you need to speak their language. In this episode, Mark DeLuzio discusses FCF %NI and why this measure is key to a successful Lean transformation.

You will never transform your company by point kaizen alone. Learn why traditional Japanese consultants were not enough in order to propel Danaher into a space all by themselves. Kaikaku (radical change) was a hallmark of Danaher’s Strategy Deployment process.

Mark discusses how companies develop On-Time Delivery KPIs (OTD) that do not reflect the customer's needs. Learn how Mark calls these "Watermelon KPIs" – GREEN on the outside and RED on the inside. Do your OTD metrics truly drive customer satisfaction?

Mark discusses building profitability into the design process via the Target Costing methodology. Roughly 70% of a product’s cost is baked into the product's design and process, leaving only 30% to Kaizen (post-design). Learn from Mark’s experience as CFO of Danaher’s JAKE Brake, where Target Costing played a significant role in JAKE’s profitability.

Mark talks about the types of Value Stream organizations and their benefits. But why are organizations reluctant to move to a Value Stream structure? Mark discusses the reasons why.

Mark talks with Jerry Wright on his new book about the ills of MRP. Jerry talks about his experience of seeing failure after failure with companies trying to perfect MRP. He argues that a Lean Transformation is impossible if MRP is used as the primary resource planning tool. MRP was first introduced in 1964 and despite its failures, is still the tool of choice for so many companies today.

Mark talks with an esteemed Lean colleague, Griselda Abousleman, whose life story should be an inspiration to all minority women, as well as to all of us who are struggling to make it in this world. Her incredible story is chronicled in her newly released book, “From the Border to the Boardroom.” Griselda talks about her upbringing in a Texas border town and her tenacity to refuse to give in when...

Most people define defects based on an engineering product specification. There is nothing wrong with this. However, in this episode, Mark DeLuzio explains why we need to broaden our thinking when it comes to defining defects.

Are you focusing on productivity as your barometer of Lean improvements? Mark DeLuzio discusses why this approach may be leading your Lean transformation into a brick wall.

Have you ever wondered why a supplier is auditing their "customer?" Mark discusses the ills of Lean Audits and the destructive culture created by those executing these audits.

It appears that the Lean Community has lost its way from the originators of Lean…that is, Toyota. Mark DeLuzio discusses the many reasons why and points out the need for us to get back to basics.

Nathan Corliss joins Mark DeLuzio to discuss the crucial topic of respect for people within lean transformation processes. As they navigate through personal anecdotes and professional insights, they discuss the significance of understanding and valuing employees' contributions and the principles of continuous improvement.

Ever wonder what a Lean Investor thinks? What they see? The questions they ask? Probably not, since there are so few in existence. In this episode, Mark talks with his long-time friend and colleague of 34 years, Cliff Ransom, of Ransom Research. As a Wall Street Analyst, Cliff covered Danaher, starting in 1990 at their Jake Brake Division. He has dedicated his professional career to the understand...

Like many poisons, they initially taste good. However, over the course of time, the poison will be your ultimate demise. Mark and Jon talk about how our metrics drive behaviors that fly in the face of Lean principles.   Most metrics today do little to truly solve a problem. Traditional accounting, Gemba Boards, and standard KPIs need to be carefully evaluated to ensure they are congruent with your...

Learn about the 7 Flows of Manufacturing as taught by our Sensei Chihiro Nakao of Shingijutsu. Jon takes us through The 7 Flows, which are easy to understand. However, not all that easy to implement. These concepts are a must if you are to call your operations “Lean.”

Mark discusses why TOC was not included in the framework of DBS and how TOC is in conflict with fundamental Lean principles. In the final analysis, it was determined that TOC offered nothing unique when compared to Lean and had the potential to drive the wrong behaviors while creating mass confusion amongst Danaher companies.

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO, about the early days at Danaher. Learn that it was more than the factory floor that had to change…more importantly, it was the mindset of Danaher’s leadership. Art and Mark discuss the history of Jake Brake and Jacobs Chuck, the two early adopters of the Toyota Productions System, as led by the disciples of Taiichi Ohno, Shingij...

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO. Art talks about the elements to create a Lean culture. In plain words, Art states that culture is defined as: “Just the way we do things here.” As you listen to Art, who pioneered one of the most successful Lean transformations at Wiremold, you will see the emphasis he places on people and his strict advice as to the changes a C...

Mark talks with Lean Horizons’ Managing Director, Kevin Mathis, about why a company needs an experienced Lean Sensei (teacher). Learn Kevin’s 5 Points of a Lean Sensei as well as what Toyota has to say about this.

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO. This Lean Pioneer has led some of the most successful Lean turnarounds in brownfield environments. Art discusses his latest publication, “The Lean Answer Book” which documents the most common questions Art had been asked in over four decades regarding Lean Transformations.

Kevin Mathis, Managing Director of Lean Horizons Consulting, talks about how he created the first Mixed Model Production cell in Danaher. In this episode, Kevin discusses how to implement a mixed model cell as well as how it all relates to the fundamentals of the Toyota Production System, specifically, JIT, Standard Work, Heijunka, Kaizen and Jidoka.

In this episode of the Lean 911 podcast, Mark DeLuzio is joined by Kevin Mathis, a Managing Director at Lean Horizons. Kevin shares insights from his extensive experience, including pioneering mixed model production at Danaher's Hennessey plant. The discussion covers the background of mixed model production, its challenges and benefits, the critical role of engaging employees in the lean transform...