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Monday, November 10, 2025

Lean Tips Edition #324 (#3886 - #3900)

For my Facebook fans you already know about this great feature. But for those of you that are not connected to A Lean Journey on Facebook or Twitter I post daily a feature I call Lean Tips.  It is meant to be advice, things I learned from experience, and some knowledge tidbits about Lean to help you along your journey.  Another great reason to like A Lean Journey on Facebook.


Here is the next addition of tips from the Facebook page:


Lean Tip #3886 – Lead with Purpose, Not Just Process

Culture change is sustained when employees clearly understand the "why" behind Lean practices. Too often, organizations jump into tools like 5S or value stream mapping without connecting them to a deeper purpose. When people know that Lean exists to make their work easier, deliver more value to customers, and strengthen the organization for the future, they begin to see change not as extra work but as meaningful work. Purpose gives people a reason to commit beyond compliance—it fuels passion and alignment.

To use this effectively, leaders must weave purpose into daily communication, not just strategy sessions. Share real stories of how Lean practices impact customers or make a team’s workday less stressful. Reinforce the bigger picture during huddles and performance reviews. Over time, this constant link between purpose and process builds a culture where employees are motivated by outcomes rather than just following orders.

Lean Tip #3887 – Model the Behavior You Expect

Leaders cannot expect employees to adopt Lean behaviors if they themselves don’t walk the talk. For example, if leaders ask teams to embrace continuous improvement but avoid gemba walks or fail to use problem-solving tools, it sends a message that Lean is optional. Culture change begins when leaders embody the same humility, discipline, and willingness to learn that they expect from their teams. The example set at the top becomes the standard for everyone else.

To apply this, leaders should participate visibly in Lean practices—join improvement events, use standard work themselves, and acknowledge when they need to improve. When employees see their leaders learning, experimenting, and even admitting mistakes, it builds trust. This consistency between words and actions is the fastest way to inspire genuine cultural adoption.

Lean Tip #3888 – Empower People to Own Improvements

A Lean culture thrives when employees see themselves as the primary agents of change, not passive executors of leadership’s vision. Too many companies stifle creativity by insisting improvements must be approved by higher-ups. Empowerment flips this script—giving employees ownership and freedom to experiment. When people realize their voices matter, energy for improvement spreads naturally.

Practically, this requires giving employees time, tools, and training to solve problems. Set up suggestion systems, run kaizen events, and celebrate every improvement, no matter the size. Even small ideas can save time, reduce frustration, or improve quality. Over time, ownership transforms culture from one of dependency to one of initiative, where employees are motivated to keep finding better ways.

Lean Tip #3889 – Make Problems Visible, Not Hidden

In traditional cultures, problems are often hidden because of fear—fear of blame, judgment, or looking incompetent. Lean flips this by treating problems as treasures, opportunities for growth that make the whole system stronger. When issues are surfaced quickly, they can be addressed before they snowball into bigger challenges. Making problems visible through boards, metrics, or huddles is a hallmark of a healthy Lean culture.

To put this into practice, create safe environments where raising problems is rewarded, not punished. Use visual management to track issues openly, and thank employees for pointing out roadblocks. Encourage teams to treat problems as collective challenges, not individual failures. Over time, employees shift from hiding problems to actively seeking them out—a powerful cultural transformation.

Lean Tip #3890 – Create a Learning Culture, Not a Blame Culture

Fear of mistakes kills innovation and slows improvement. In a blame culture, employees hesitate to try new things or speak up, because they worry about being punished. A Lean learning culture instead views mistakes as data points to understand, explore, and learn from. This reduces fear and encourages curiosity.

Leaders can set the tone by asking "what happened" instead of "who is at fault." Celebrate lessons learned and use them to prevent recurrence rather than to assign guilt. Over time, this shift fosters psychological safety, making employees more comfortable experimenting. A learning culture accelerates improvement by turning every misstep into fuel for growth.

Lean Tip #3891 – Align Metrics with Cultural Goals

Metrics shape behavior, so when they are misaligned, culture suffers. If leaders measure only speed or output, employees may feel pressured to cut corners. If quality and collaboration aren’t measured, they won’t be prioritized. To build a Lean culture, metrics must reflect not just results but also the process and values that drive them.

Introduce balanced metrics that emphasize improvement efforts, employee engagement, and customer satisfaction alongside traditional measures. For example, track the number of implemented ideas or the frequency of root cause problem-solving sessions. Reinforce the idea that how results are achieved matters as much as the results themselves. This alignment ensures culture change sticks. 

Lean Tip #3892 – Tell Stories that Reinforce Change

Numbers and charts may inform, but stories inspire. A Lean culture grows when employees hear examples of their peers making improvements, solving problems, or creating better outcomes for customers. Stories make culture personal and relatable, connecting people emotionally to the change effort.

Leaders should regularly share stories during meetings, in newsletters, or even informally during gemba walks. Highlight not just the improvement but the journey—the teamwork, learning, and persistence that made it possible. As these stories spread, they create an organizational narrative that Lean is not just a program, but a way of life.

Lean Tip #3893 – Start Small, Scale Fast

Trying to change everything at once often leads to fatigue and resistance. Culture change works best when it begins with small, visible wins that prove Lean principles work. Once people see results, they begin to believe in the possibility of broader change.

The key is to start with manageable initiatives—like improving a team’s meeting process or reducing waste in a single area—then expand. Share the results widely and invite other teams to try similar efforts. Success creates momentum, and soon the culture begins shifting organically as improvements spread.

Lean Tip #3894 – Break Down Silos with Collaboration

Siloed organizations breed inefficiency, finger-pointing, and a lack of shared accountability. Lean culture thrives when teams collaborate across boundaries, bringing diverse perspectives to solve problems. When collaboration becomes the norm, improvement accelerates.

Leaders can foster this by organizing cross-functional kaizen events, encouraging job shadowing, or rotating roles to build empathy. Provide platforms for teams to share best practices and learn from each other. Breaking silos isn’t just about efficiency—it builds a sense of unity that strengthens the culture across the entire organization.

Lean Tip #3895 – Respect Every Individual, Every Day 

Respect for people is the foundation of Lean. Without it, tools and processes are hollow. Employees must feel valued not just for what they produce, but for who they are and what they contribute. Respect builds trust, which is essential for cultural transformation.

Show respect by listening to employee concerns, acting on feedback, and recognizing contributions. Avoid token gestures—respect is proven through consistent daily actions. When employees truly feel respected, they give more of their creativity, commitment, and discretionary effort, fueling a stronger culture.

Lean Tip #3896 – Embed Continuous Improvement into Daily Work 

If improvement is treated as something separate from regular work, it won’t become cultural. Lean requires integrating improvement into the daily rhythm of operations so that employees constantly look for better ways of working. 

Leaders should create time for teams to reflect and problem-solve each day. Encourage people to ask: “How can this task be done better tomorrow?” Provide quick feedback loops so improvements don’t stall. By making continuous improvement part of daily habits, organizations embed Lean into their DNA. 

Lean Tip #3897 – Celebrate Progress, Not Just Perfection 

A culture obsessed with perfection can paralyze employees, making them afraid to act until conditions are ideal. Lean celebrates progress—valuing small steps forward that accumulate into major improvements over time. This mindset encourages action and experimentation. 

Recognize incremental improvements and highlight them across the organization. Share how small changes create ripple effects for customers or teams. By praising progress, leaders signal that every contribution matters and perfection is not the goal. This builds confidence and energy to keep improving.

Lean Tip #3898 – Develop Leaders at Every Level of Your Company

Sustainable culture change cannot rest on a few senior leaders—it requires leadership distributed across the organization. In a Lean environment, leadership is about coaching, enabling, and modeling problem-solving, regardless of title.

To cultivate this, invest in training frontline supervisors and team leads in Lean leadership skills. Encourage employees to take ownership in their areas and mentor them in guiding others. As leadership spreads throughout the organization, culture becomes self-sustaining and less dependent on top-down direction. 

Lean Tip #3899 – Stay Consistent, Even When It’s Hard

The true test of culture comes during crises. If Lean principles are abandoned under pressure, employees will quickly realize the commitment was conditional. Consistency builds credibility and resilience.

Leaders must hold firm to Lean values even in stressful times—whether that means continuing daily huddles during a production crunch or solving problems methodically instead of firefighting. Employees notice when leaders stay steady, and this consistency reassures them that Lean is not just a fad but a permanent cultural shift.

Lean Tip #3900 – Connect Culture to Customer Value

At the end of the day, Lean is about creating more value for the customer. Employees are more likely to embrace change when they understand how their efforts improve the customer’s experience. This connection gives meaning and pride to their work.

Leaders should regularly share customer feedback and success stories, linking improvements directly to outcomes like better quality, faster delivery, or happier clients. Show employees how their actions ripple outward to create real impact. A culture anchored in customer value ensures Lean becomes more than internal efficiency—it becomes a purpose-driven movement.


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Friday, November 7, 2025

Lean Quote: Better Over Perfection – Lean Lesson from Bruce Lee

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.


"A goal is not always meant to be reached; it often serves simply as something to aim at.  —  Bruce Lee

Bruce Lee once said, “A goal is not always meant to be reached; it often serves simply as something to aim at.” This perspective is particularly relevant in the context of Lean thinking, where continuous improvement is the guiding principle. In Lean, we recognize that perfection is a moving target. The real value of setting goals is not in achieving an absolute endpoint, but in creating focus, direction, and momentum for improvement. Goals give teams a clear sense of purpose, even if the ideal state remains just beyond reach.

In Lean, the concept of True North embodies this idea. True North represents the organization’s highest aspirations—perfect quality, zero waste, total customer satisfaction. We may never fully arrive, but by consistently moving toward True North, we drive meaningful change. It’s not about flawless execution from day one, but about aligning our actions and decisions with where we want to go. This mindset keeps teams moving forward instead of becoming paralyzed by the fear of not hitting the target exactly.

Too often, organizations fall into the trap of “perfection paralysis.” They wait for the perfect plan, the perfect resources, or the perfect moment before taking action. In Lean, progress is more important than perfection. We learn by doing—by testing ideas, adjusting based on feedback, and making small, incremental improvements. A goal provides the framework for this learning, even if the path changes along the way.

Moreover, when teams view goals as guiding stars rather than rigid endpoints, they are more willing to experiment and adapt. A missed metric is no longer seen as failure, but as a learning opportunity. This fosters a culture where employees are engaged in problem-solving and innovation, because they know the journey is just as important as the destination. The focus shifts from “Did we hit the goal?” to “What did we learn as we worked toward it?”

Ultimately, Bruce Lee’s insight reminds us that in Lean, the pursuit of improvement is ongoing. The act of aiming at a goal—striving, learning, adjusting—is what transforms organizations. Better is always within reach, while perfection remains the horizon that keeps us moving. By embracing this philosophy, we create a workplace that values action over hesitation, progress over perfection, and learning over static achievement.

If we keep our eyes on True North, we’ll find that every step, no matter how small, moves us closer to a better way of working. The goal is not to “arrive” but to keep improving—always aiming higher, always striving for better. That’s the real spirit of Lean.

Wednesday, November 5, 2025

Build A Culture of Empathy


Empathy is a transformative force in business and life that allows leaders and managers to empower those around them. Beyond numbers and profits, understanding and connecting with others on an emotional level is a hallmark of exceptional leadership.

Empathy in leadership goes beyond just a soft skill; it's a strategic imperative. As a manager, your interactions shape the team's culture and morale. By understanding your employees' feelings, needs, and perspectives, you forge connections that are the bedrock of trust and collaboration.

Empathy is the cornerstone of a positive work environment. When leaders genuinely care about their team members' well-being, it creates a culture of camaraderie. Employees feel valued and appreciated, resulting in increased job satisfaction, higher morale and reduced turnover. By acknowledging individual strengths and challenges, leaders can tailor their approach, empowering employees to thrive and contribute their best.

Here are 28 tips to help:

·       Listen and don’t interrupt

·       Focus 100% on the other person

·       Be FULLY present (don’t have your phone nearby)

·       Use people’s names

·       Be nice and care

·       Do not take it in turns to talk

·       Put yourself in their shoes

·       Don’t judge

·       Acknowledge the person’s feelings

·       Ask questions

·       Don’t assume

·       Ensure your body language is spot on

·       Don’t finish off sentences

·       Summarize your understanding

·       Allow the person to rant

·       Get to know others personally

·       Make it about them and not you

·       Smile

·       Park your beliefs

·       Say “Thank you”

·       Accept feedback

·       Accept disagreement

·       Don’t give advice too soon

·       Use “we” not “me”

·       Look at it from different angles

·       Don’t have all the answers

·       Be open

·       Ask how you can help

Empathy is contagious. When leaders embody compassion, their teams often emulate this behavior. This ripple effect extends to customer and client interactions, creating authentic connections that enhance customer loyalty and satisfaction. A company culture rooted in empathy can differentiate the organization in a competitive marketplace.


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Monday, November 3, 2025

The 2025 Northeast Lean Conference at a Glance


The 21st Annual Northeast Lean Conference, held October 27-28, 2025 in Manchester, New Hampshire, brought together hundreds of Lean and continuousimprovement practitioners across manufacturing, services, and administrative arenas. The theme—“Transforming Together: Paving a Unified Path to Excellence”—set the tone for two days of inspiration, networking and actionable learning.

Attendees were treated to three compelling keynote addresses, a variety of breakout sessions (including my own), and plenty of peersharing time to connect and learn from fellow Lean journeys.

Keynote Highlights

Derek Volk – Opening Keynote

Derek Volk kicked off the event with a high-energy talk rooted in his leadership of Volk Packaging Corporation and his experience coaching girls’ softball. He used the sports metaphor to underscore what sustainable improvement really looks like: purpose, team alignment, culture, and execution. His key messages included:

  • Don’t treat Lean just as tools—think of it as “team sport”.
  • Aim for “third base” not just first or second—meaning go beyond incremental wins and aim for system-wide alignment and culture.
  • Engage people not just processes: trust, communication and continuous learning matter.
    Attendees left with a renewed lens: how are we doing on team dynamics, not just on process metrics?

Jordan Peck – Day One Closing Keynote

Jordan Peck (of MITRE Corporation) delivered the closing keynote on Day 1, titled “Transforming Together: Set a Vision, Learn & Evolve.” In his session:

  • He emphasized the importance of setting a shared vision to guide improvement efforts across functions.
  • He discussed how learning loops and reflection mechanisms embed improvement beyond “kaizen events”.
  • He challenged participants to evolve their systems and culture continuously—and not just chase the next tool.
    What resonated: improvement isn’t finished when a metric improves; it’s ongoing adaptation.

Miles Arnone – Day Two Keynote

On Day 2, Miles Arnone of Re:Build Manufacturing delivered a talk focused on building resilience and innovation in Lean transformation. Major takeaways:

  • Build systems expecting variability: supply chain, staffing, market change—resilience matters.
  • Embed innovation into day-to-day operations, not as a separate program.
  • Culture is the engine of Lean: tools alone won’t sustain change if culture doesn’t adapt.
    So the message: your improvement system must be dynamic, not static.

My Presentation – “Our Path to Transformation & Operational Excellence”

On Day 1, I shared Mirion’s Lean transformation journey. The session offered a practical look at how a global organization is aligning strategy, systems, and culture to build sustainable operational excellence.

The talk centered around the Mirion Business System (MBS) — our structured approach to deploying Lean thinking across the enterprise. MBS is built on five key enablers: Organization and Talent, Strategy Deployment, Market Driven Strategy, Innovation Driven Strategy, and Lean, all working together to drive execution excellence and deliver customer value.

Key highlights included:

  • Strategy Deployment (Hoshin Kanri): A seven-step process connecting company vision and long-term breakthrough goals with annual objectives and tactical improvement priorities. I emphasized how Mirion uses tools like the X-Matrix, TTI Bowler charts, and structured monthly reviews to ensure alignment and accountability.
  • Daily Management & Problem Solving: We discussed the relationship between Strategy Deployment (SDP) and Daily Performance Management (DPM)—how breakthrough goals translate into daily behaviors. Visual boards, standard work, and tiered huddles enable teams to identify and act on problems in real time.
  • Kaizen and Flow Improvement: Using examples from Mirion’s value streams, I shared how systematic kaizen cycles have shortened lead times, improved flow, and boosted productivity.
  • Cultural Transformation: The session highlighted Mirion’s improvement philosophy—S.O.L.V.E.: See Opportunities, Own Resolution, Learn to Adapt, Value Add, Engage Everyday. This mindset anchors every level of the business in continuous learning and engagement.
  • Results: The transformation is producing tangible outcomes—double-digit improvements in on-time delivery, inventory reduction, gross margin, and employee engagement—all tied to Lean fundamentals and leadership commitment.

I concluded by encouraging attendees to focus on building capability and culture, not just chasing cost or metric gains. Sustaining Lean success requires aligning purpose with process, empowering people, and embedding reflection into daily work.

Looking Ahead: Next Year & Your Invitation

Mark your calendar now for the 22nd Annual Northeast Lean Conference, taking place September 29-30, 2026, at the MassMutual Center in Springfield, Massachusetts.

The theme for 2026 is “People & AI: The Future of Continuous Improvement.”

This signals a bold step into how organizations can harness both the human side of Lean—and emerging tools like artificial intelligence—to accelerate improvement, build resilience and deliver greater value.

Register by the Wicked Early Bird deadline (Nov 30, 2025) to save significantly $1,895.00 $895.00. Together, we’ll keep paving that unified path toward excellence.

Final Thoughts

The Northeast Lean Conference remains one of the premier Lean learning events in the country—an energizing mix of real stories, practical lessons, and genuine community. This year’s speakers—Derek Volk, Jordan Peck, and Miles Arnone—each offered powerful perspectives on leadership, culture, and resilience, while the breakout sessions and discussions connected those ideas to everyday practice.

As we reflect on 2025’s theme of Transforming Together, let’s remember that Lean is not a solo journey. Progress happens when we learn, share, and grow—together.

Let’s keep that spirit alive in our organizations and on our Lean journeys. See you in Springfield next year!


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Friday, October 31, 2025

Lean Quote: It’s the Great Pumpkin, Charlie Brown – A Lean Lesson in Continuous Improvement

 

On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.


"Well, another Halloween has come and gone.  —  Charlie Brown, It's the Great Pumpkin, Charlie Brown

Since 1966, “It’s the Great Pumpkin, Charlie Brown” has charmed audiences with the story of Linus faithfully waiting in the “most sincere” pumpkin patch for the Great Pumpkin. While the rest of the Peanuts gang goes trick-or-treating, Linus holds onto his belief—year after year—only to be disappointed. Sally misses candy, Charlie Brown gets rocks, and Linus vows to try again next Halloween without changing a thing.

That’s a fun Halloween tradition, but in the world of continuous improvement and Lean, repeating the same process without learning or adjusting is a recipe for waste. Like Linus, many organizations “wait in the pumpkin patch” for results that never come — hoping instead of acting.

From a lean and continuous improvement perspective, there are steps you can take to act instead of relying on hope.

1. Validate Your Processes
Linus assumes sincerity alone will bring results. In lean, good intentions aren’t enough—processes must be tested, measured, and confirmed to deliver the intended outcome. Before committing resources year after year, ask: Does this work under real conditions?

2. Continuously Monitor Performance
Linus never checks his “process” in real time. In lean, continuous monitoring means tracking key measures, spotting variation early, and making timely adjustments. Don’t wait until the next “Halloween” to discover results aren’t meeting expectations.

3. Adapt to Changing Conditions
Regulations, markets, and customer needs evolve. The best lean systems are flexible, learning from feedback and changing accordingly. Unlike Linus, who repeats the same approach, continuous improvement means evolving based on data.

4. Build Buy-In Across the Team
Linus couldn’t convince others to join his mission. Lean thrives when everyone understands the purpose, sees the value, and contributes to problem-solving. Engagement across all levels keeps improvement efforts from being a “solo vigil.”

Lean teaches us to replace blind hope with learning, experimentation, and adaptation. Whether on the shop floor or in the office, improvement comes from cycles of Plan → Do → Check → Adjust — not simply waiting for “next year” to be better.

The Takeaway
In lean, we don’t sit in the pumpkin patch year after year hoping for different results. We validate, measure, adjust, and involve the team so improvement is real—not wishful thinking. This Halloween, let’s channel the optimism of Linus and the resilience of Charlie Brown—but add the rigor of continuous improvement to make sure our Great Pumpkin actually shows up.


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Wednesday, October 29, 2025

Lean Roundup #197 – October 2025


A selection of highlighted blog posts from Lean bloggers from the month of October 2025.  You can also view the previous monthly Lean Roundups here.  

 

From Know-It-All to Learn-It-All: Leadership Lessons from Mistakes – Mark Graban shares that shift–from know-it-all to learn-it-all–doesn't weaken leaders, it makes them stronger, more resilient, and more effective.

 

Transforming Together – Bruce Hamilton focuses on creating a work environment favorable to personal and organizational growth.

 

How UMass Memorial Health Built a Culture of Continuous Improvement - Danielle Yoon summarizes key insights from a comprehensive whitepaper detailing UMass Memorial Health's remarkable transformation journey.

 

From MBO to Hoshin Kanri – Michel Baudin explains why Hoshin Kanri has surpassed management by objectives (MBO) approach to performance.

 

Ambidexterity – the Leadership Challenge – Pascal Dennis says senior leaders & the Board need to learn & practice two different mindsets and ways of working.

 

What Is Hitozukuri? – Christoph Roser explains what Hitozukuri is, and that it’s indeed a spin-off of monozukuri, and the idea is to grow your people.

 

Prediction Machines: Why We Might Be More Like AI Than We Think – Kevin Meyers says that our brains might be nothing more than sophisticated prediction machines, and what we've long cherished as "free will" could simply be the emergent property of complex pattern recognition.

 

Developing People into Problem Solvers – Alen Ganic shares five key steps organizations can do is to develop its people with the best chance of success.

 

Micromanagement Is Not Respect for People – John Knotts explains that micromanagement is not a successful leadership style and how leaders can demonstrate true respect.

 

Do Hard Things – Ron Pereira says continuous improvement gives us opportunity to do hard things, build strong teams, and create better systems that last.

 

Continuous Improvement Eliminates Excess Overtime – Ricky Banks shares five CI strategies that you can employ to immediately address overtime in your company.

 

Coaching Others to Achieve Breakthrough Performance – Josh Howell and Mark Reich explore how CI groups engage leaders, balance problem-solving with capability building, and drive lasting cultural change—featuring insights from Toyota, GE Appliances, and Cleveland Clinic.

 

The Chief Engineer Advantage: Turning Tension Into Breakthroughs – James Morgan shows how conflict isn’t something chief engineers avoid—it’s what they harness.

 

Why the Toyota Production System Remains Elusive for Most Companies – Bruce Watkins explores why the Toyota Production System remains elusive despite decades of proven success—most companies misunderstand it as a set of manufacturing tools rather than a complete economic system built on philosophy, technical methods, and human development.

 

The Deadly Cost of Ignoring Lockout/Tagout: What Lean Leaders Must Learn – Mark Graban explains there is no such thing as Lean without safety.


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