The Lean Solutions Podcast

What You’ll Learn in This Episode: In this episode, Patrick Adams, Catherine McDonald, Shayne Daughenbaugh, and Andy Olrich unpack the hidden costs that quietly erode margins, and why most organizations don’t see them coming. You’ll learn how these costs often live outside traditional financial statements, showing up instead as rework, inefficiencies, poor handoffs, and constant interruptions like...

What You’ll Learn in This Episode: In this episode, Patrick Adams and Shayne Daughenbaugh break down the true meaning of GEMBA and why it’s a foundational practice in Lean leadership. You’ll learn how going to the “real place” helps leaders move beyond assumptions and understand what’s actually happening in their processes. The conversation highlights why many leaders avoid the gemba. Often due to...

What You’ll Learn in This Episode: In this episode, Patrick Adams sits down with Cindy Darnell to explore how behavioral assessments like DISC can transform leadership, communication, and team performance. You’ll learn how understanding personality styles helps leaders adapt their communication, reduce conflict, and build stronger relationships across teams. Cindy shares practical examples of how...

What You’ll Learn in This Episode: In this episode, Catherine McDonald and Shayne Daughenbaugh explore the power of small, everyday improvements. What they call the “10-minute improvement.” Instead of focusing only on large-scale Lean projects, they break down how organizations can unlock hidden opportunities by addressing small frustrations, workarounds, and communication gaps that often go unnot...

What You’ll Learn in This Episode: In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent dive into the real starting point of Industry 4.0—shifting from “proof of concept” to “proof of value.” You’ll learn why simply collecting machine data isn’t enough, and how to tie that data directly to financial outcomes that matter to leadership. The conversation breaks down practical first s...

What You’ll Learn in This Episode: In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent break down what Industry 4.0 really means, and why it’s not as complex or expensive as many think. You’ll learn how to start small , connect existing systems, and use data more effectively to improve operations. The conversation highlights why Industry 4.0 is about integration, not technology ,...

What You’ll Learn in This Episode: In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald break down one of the biggest reasons Lean fails in organizations, and how it has nothing to do with the tools. Most companies try to “sell Lean” as a program or initiative, which immediately creates resistance. Employees see it as something being done to them instead of for them ....

What You’ll Learn in This Episode: In this episode of the Lean Solutions Podcast, Patrick Adams and Shayne Daughenbaugh sit down with Lean expert Darren Walsh to uncover why most Lean transformations stall, and what leaders must do to accelerate real business transformation. With more than 25 years of experience working with world-class organizations, Darren explains why many companies struggle wi...

What You’ll Learn in This Episode: In this episode of the Lean Solutions Podcast, hosts Patrick Adams and Shayne Daughenbaugh are joined by Marco Dannerhill to explore how Lean thinking must evolve in today’s fast-changing business environment . Drawing on more than three decades of experience in the plastics industry, Marco shares how Lean has shifted from focusing on localized process improvemen...

What You’ll Learn in This Episode : In this episode of the Lean Solutions Podcast, hosts Patrick Adams, Andy Olrich, and guest Steve Riley discuss the importance of leadership behaviors in maintaining Lean initiatives. They highlight how unintentional actions, such as not picking up trash or not following standard work, can undermine Lean efforts. Steve Riley, a manufacturing operations leader wit...

What You’ll Learn in This Episode : In this second part episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh discuss the initial steps for a new leader implementing Lean principles. They emphasize understanding the current state through one-on-one interviews and Jeff Liker's leadership development model, which includes personal development, coaching others, daily Kaizen, and...

What You’ll Learn in This Episode : In this episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh explore what the first 90 days should look like after discovering Lean or stepping into a new organization. Once someone understands the principles of continuous improvement, what should they actually do first? They discuss how your approach must shift depending on your level of...

What You’ll Learn in This Episode: In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald explore what happens after the strategy day is over . Once goals are set, how do organizations move from planning to real execution? They highlight the challenges of managing too many goals and the necessity of engaging teams in the strategy process.  They unpack why teams often str...

What You’ll Learn in This Episode In this episode, hosts Catherine McDonald and Shayne Daughenbaugh discuss what coaching in the workplace really means. Why it’s far more than a buzzword. The conversation breaks down the difference between coaching, training, and mentoring, and explains how coaching serves as a powerful leadership approach for developing people, building trust, and sustaining cont...

What You’ll Learn:  The second half dives deeper into the people side of continuous improvement . Dave explains how Nemawashi and intentional conversations help build alignment, trust, and momentum. Listeners learn why asking thoughtful questions—like “who else should we talk to?”—can naturally expand buy-in and lead to better decisions. The episode wraps with reflections on leadership, learning,...

What You'll Learn: In the first half of the episode, the conversation focuses on the foundations of effective change and project success . Dave shares insights on the importance of executive support, strong project management, and understanding the real problems teams are trying to solve. The discussion highlights why improvement efforts often stall and how leaders can create clarity by engaging t...

The Lean Solutions Podcast hosts start off season 5 by addressing a common challenge: setting goals is easy, but making them stick is not. They emphasize that meaningful goal setting requires clarity, alignment, and intention, warning that vague goals and misaligned priorities often lead teams off track. From the start, they frame goals as something that must connect directly to daily work and org...

What You’ll Learn: Join the Lean Solutions Podcast hosts as they discuss the importance of reflection and goal-setting for 2026. They shared personal reflections on habits, such as overcooking presentations and non-use of talent, and the significance of being grounded and customer-focused. The team also discussed the eight wastes of lean to identify and improve personal habits. Links: Lean Solutio...

What You’ll Learn: In this episode, host Patrick Adams interviews Natalie Howden, a new team member at Lean Solutions, about her career journey and the importance of standard work in Lean environments. Natalie shares her background in pharmaceuticals, lithium-ion, and office furniture, highlighting her transition from a scientist to a Lean Six Sigma Black Belt. She emphasizes the value of standard...

What You’ll Learn: In this episode, host Catherine McDonald and guest Kelly Mallery discuss the importance of understanding and managing resistance to change in the workplace. They emphasize that resistance is a natural human reaction rooted in fear and that fighting it can be counterproductive, leading to eroded trust and failed change initiatives. About the Guest: Kelly Mallery has built her car...

What You’ll Learn: In this episode, hosts Andy Olrich, Catherine McDonald, and guest Wendy Sellers discuss positive leadership. They define positive leadership as focusing on strengths, optimism, and psychological safety, which fosters continuous improvement through ongoing learning and experimentation. They emphasize the importance of accountability, high standards, and clear company values. Wend...

What You’ll Learn: In this episode, hosts Andy Olrich, Shayne Daughenbaug, and guest Alex Suchman discuss how play can serve as a powerful tool for continuous improvement and stronger team performance. They highlight how workplace disagreement often stems from interpersonal dynamics and different communication styles. They also emphasize that play can foster trust, accountability, and psychologica...

What You’ll Learn: In this episode, hosts Patrick Adams and Andy Olrich discuss the importance of soft skills in leadership, emphasizing empathy, communication, adaptability, and emotional intelligence. About the Guest: Andy Olrich brings over 25 years of expertise in engineering trades, services, manufacturing, mining and logistics processes and support. With qualifications in Continuous Improvem...

What You’ll Learn: In this episode, hosts Catherine McDonald, Andy Olrich, and guest Leire Martinez discuss the importance of sustaining culture and connection in organizations. They emphasize that culture is crucial for continuous improvement and can vary across different departments and regions. About the Guest: With a strong Lean Six Sigma background, she is experienced as an Operations Directo...

What You’ll Learn: Patrick Adams discusses his experience on the "Blox" show, a live startup competition. He was motivated by the opportunity to learn and apply new skills to his business, Lean Solutions. The show, which features 100-150 businesses, is hosted by Wes Bergman and involves daily classroom sessions and challenges. Patrick emphasizes the importance of simplifying business explanations...