Floor Tape Store

Monday, October 20, 2025

Lean Tips Edition #323 (#3871 - #3885)

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 #3871 – Lead by Example, Not by Directive

One of the most powerful tools a leader has is consistency between their words and actions. In Lean, this means showing commitment to the principles of respect, problem-solving, and continuous improvement by the way you personally work. If you demand accountability but don’t practice it yourself, your credibility erodes quickly.

When leaders visibly participate—walking the floor, using problem-solving tools, or embracing feedback—they set the tone for the entire organization. People take their cues from leadership behavior. If you want your team to embrace Lean, they must see it in action through you first.

Lean Tip #3872 – Go to the Gemba (The Real Place)

Decisions made far from the work often miss the realities employees face. That’s why Lean leaders prioritize Gemba walks—visiting the actual workplace where value is created. Seeing processes firsthand helps you connect observations with data, uncover issues that might not appear in reports, and build relationships with employees.

When done with humility, Gemba visits demonstrate genuine respect for your people. Instead of “policing,” you’re learning. Ask employees to explain their work, listen to their frustrations, and thank them for insights. Over time, this builds trust and leads to better-informed decisions.

Lean Tip #3873 – Ask Questions Before Giving Answers

It’s tempting as a leader to provide quick solutions. But Lean leadership emphasizes coaching over directing. By asking thoughtful, open-ended questions, you encourage employees to engage their critical thinking and problem-solving skills. Questions like “What do you think the root cause is?” or “What would you try first?” empower people to take ownership.

This shift changes your role from “chief firefighter” to “capability builder.” Over time, teams gain confidence and skills to tackle problems independently. That not only reduces your burden but creates a culture where improvement is driven from every level, not just the top.

Lean Tip #3874 – Respect People by Listening Deeply

Respect for people goes beyond polite words—it requires intentional listening. When team members bring forward ideas or frustrations, Lean leaders pause, give full attention, and listen without preparing a counterargument. This demonstrates trust and shows that every voice has value.

Deep listening often uncovers process issues or opportunities for improvement that wouldn’t surface otherwise. Employees on the frontlines usually know where the real challenges are. When they see their input leading to action, engagement grows, and your culture of continuous improvement strengthens.

Lean Tip #3875 – Eliminate Blame, Focus on Process

When errors occur, many leaders instinctively look for someone to hold accountable. But Lean leaders recognize that 90% of problems stem from process weaknesses, not people. Shifting the focus from blame to learning creates a safer environment for employees to speak up about issues.

Instead of asking, “Who caused this?” ask, “What in the process allowed this to happen?” This approach uncovers systemic issues and leads to sustainable fixes. Over time, it builds trust—because people know mistakes won’t ruin them, but instead become opportunities for shared learning.

Lean Tip #3876 – Make Continuous Improvement Daily Work

Improvement isn’t something you do only during formal Kaizen events. True Lean leaders integrate improvement into the daily rhythm of work. That may include short reflection meetings, quick idea boards, or 5-minute process checks where employees can raise and address small issues.

When improvement becomes part of daily work, it stops feeling like “extra” effort. Employees see small problems being solved consistently, which builds momentum and confidence to tackle larger challenges. This steady, incremental progress compounds into significant results over time.

Lean Tip #3877 – Develop People, Not Just Processes

It’s easy to focus only on improving systems, but Lean recognizes that strong processes require skilled and engaged people. Leaders should invest in coaching, mentoring, and providing opportunities for employees to stretch into new challenges. Developing people builds long-term organizational strength.

When you help someone learn problem-solving skills, or support them through training and career growth, you’re not just solving today’s issues—you’re equipping them to handle tomorrow’s. Leaders who prioritize development create teams that can adapt, innovate, and sustain improvement without constant direction.

Lean Tip #3878 – Create Clarity Through Visual Management

Confusion slows teams down. Lean leaders reduce this by making information visible and easy to understand. Visual boards, color coding, simple charts, and floor markings help everyone know what’s happening, what the goals are, and where attention is needed.

This kind of transparency empowers teams to act without waiting for instructions. It reduces wasted time, improves alignment, and fosters accountability. When goals and progress are clearly visible, conversations shift from “What’s going on?” to “How can we improve this?”

Lean Tip #3879 – Standardize, but Stay Flexible

Standard work is the backbone of Lean—it provides stability and ensures consistency. But leaders must communicate that standards are not meant to stifle innovation. Instead, they represent the best-known method today and are always open to improvement.

Encourage your team to use standards as a baseline while remaining open to better ways of working. When someone finds a new, more effective method, update the standard. This mindset balances discipline with adaptability, creating a culture of learning rather than rigidity.

Lean Tip #3880 – Foster a No-Fear Culture of Experimentation

Fear kills creativity. Lean leaders encourage experimentation by creating psychological safety. Instead of demanding flawless solutions, promote the idea of “try small, learn fast.” A failed experiment is not a mistake—it’s a data point that brings you closer to the right answer.

When employees know they won’t be punished for taking initiative, they feel empowered to propose and test new ideas. Over time, this builds an innovative culture where continuous learning is the norm and breakthroughs emerge from small, low-risk trials.

Lean Tip #3881 – Align Around Purpose, Not Just Metrics

Metrics are important for measuring progress, but they don’t inspire people on their own. Lean leaders connect the work to a greater purpose—whether it’s delighting the customer, improving safety, or contributing to the community. Purpose gives meaning to tasks and builds pride in the work.

When employees understand why their efforts matter, motivation deepens. Teams stop chasing numbers for their own sake and begin striving toward something bigger. This sense of shared purpose creates alignment and energy that no performance dashboard can achieve alone.

Lean Tip #3882 – Slow Down to Go Fast

In the rush of daily operations, it’s tempting to push for quick fixes. But in Lean, slowing down to deeply understand a problem prevents wasted effort and rework later. Tools like root cause analysis and PDCA cycles encourage this thoughtful pace.

When leaders emphasize understanding before acting, they signal that thoroughness matters more than speed. Ironically, this “slower” approach often produces faster long-term results because solutions stick, processes improve, and problems don’t resurface.

Lean Tip #3883 – Recognize and Celebrate Small Wins

Big transformations are made up of countless small improvements. Lean leaders make a point to recognize and celebrate these incremental wins. Whether it’s a simple “thank you” in a meeting, a visible improvement board, or a small celebration, acknowledgment builds momentum.

Recognition reinforces the behaviors you want to see repeated. It also shows that leadership values the contributions of frontline employees. Over time, celebrating small wins creates an energized environment where improvement becomes contagious.

Lean Tip #3884 – Teach Problem-Solving as a Core Skill

A Lean leader’s job isn’t to solve every problem—it’s to teach others how. Building problem-solving skills across the organization ensures that improvement continues at every level. Encourage the use of PDCA, root cause analysis, and structured thinking.

As employees become more capable problem solvers, leaders can focus on removing barriers and coaching rather than firefighting. This distributed problem-solving capability creates resilience and allows your organization to adapt quickly to new challenges.

Lean Tip #3885 – Be a Servant Leader, Not a Boss

At its heart, Lean leadership is about service. Instead of commanding from above, servant leaders ask, “What do my people need to succeed?” This mindset shifts the role of leadership to enabling—removing obstacles, providing resources, and empowering employees to make improvements.

When teams know their leader is invested in their success, trust deepens. People feel safe to bring up issues, propose ideas, and take ownership of their work. Over time, servant leadership builds loyalty, strengthens engagement, and drives sustainable performance.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Friday, October 17, 2025

Lean Quote: Closing the Knowing–Doing Gap

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.


"The greatest gap in the world is the gap between knowing and doing.  —  John C. Maxwell

Many organizations are full of smart people who know exactly what should be done—yet, somehow, it doesn’t get done. This gap between knowledge and action costs time, opportunities, and momentum.

Managers often see valuable opportunities, but hesitation, over-analysis, or fear of mistakes prevents them from starting. Even when they do start, the first obstacle can stop progress cold. The inability to take purposeful action is widespread, and crucial issues requiring reflection, planning, creativity, and consistent effort often get postponed indefinitely.

If you do nothing, nothing changes. Inertia is powerful—things at rest tend to stay at rest. And while it’s natural to want the perfect plan before taking action, perfection is the enemy of momentum. A 50% improvement implemented today beats a theoretical 100% improvement that never leaves the whiteboard.

The only cure for inactivity is action. The first step in building a culture of execution is creating a bias toward action—making “do something now” the default.

How to Reduce the Gap Between Knowing and Doing

  1. Start Small, Start Now
    • Break large goals into quick, low-risk actions you can take immediately.
    • Example: Instead of analyzing a process problem for weeks, run a quick trial solution on one workstation.
  2. Make It Safe to Try—and Fail
    • Reward initiative, not just outcomes.
    • Treat mistakes as learning investments, not career-limiting moves.
  3. Set Short Feedback Loops
    • Replace long, drawn-out project cycles with rapid check-ins and adjustments.
    • Quick learning cycles make it easier to see progress and maintain momentum.
  4. Measure Action, Not Just Ideas
    • Track “execution metrics” like number of experiments run, pilot projects launched, or issues resolved—not just meetings held or plans made.
  5. Recognize and Celebrate Movers
    • Publicly acknowledge employees who move projects forward, even in small ways.
    • Stories of action create peer pressure to act.
  6. Simplify the First Step
    • Remove unnecessary approvals, overly complex templates, or ambiguous ownership that slow down action.
  7. Model It From the Top
    • Leaders must be the first to move from idea to test. When the team sees action modeled at the top, it becomes part of the culture.

By reducing the friction between knowing and doing, you create an environment where action is the norm, hesitation is the exception, and learning comes from trying. The knowing–doing gap doesn’t close by thinking harder—it closes by acting sooner.


Wednesday, October 15, 2025

Improving Your Business with Lean Thinking and a Growth Mindset


Organizations that want to thrive in today’s unpredictable markets must develop leaders who not only embody a growth mindset but also apply Lean Thinking to drive sustainable improvement. The business landscape is shifting rapidly, and winning now means being pragmatic, data-driven, and relentlessly focused on creating customer value while eliminating waste.

Why Combine Growth Mindset with Lean Thinking?

Psychologist Carol Dweck defines the growth mindset as the passion for stretching yourself and persevering, even when it’s not easy. Lean Thinking shares this DNA—both require curiosity, openness to change, and the courage to challenge the status quo.

Instead of proving how great you already are, Lean-minded leaders continuously ask, How can we improve this process? How can we create more value with fewer resources?

Four Mindset Shifts for Lean Success

1. Growth vs. Fixed Mindsets – Learning to See Waste

Leaders with a growth mindset believe capabilities can be developed through effort and learning. In Lean, this translates to learning to see waste and encouraging teams to experiment with better ways of working. Those with a fixed mindset resist change and may accept inefficiency as “just the way it is.”

Lean action: Train teams to identify the 8 wastes (defects, overproduction, waiting, etc.) and empower them to eliminate them.

2. Learning vs. Performance Mindsets – Continuous Improvement over “Looking Good”

A learning mindset thrives on skill development, experimentation, and problem-solving—core elements of Kaizen. A performance mindset seeks recognition for achievements, which can sometimes discourage risk-taking and innovation.

Lean action: Measure success not only by results but also by the number of improvement ideas implemented and lessons learned.

3. Receptive vs. Implemental Mindsets – Listening to the Gemba

A receptive mindset values others’ input and recognizes that the best improvements often come from those closest to the work. In Lean, this means going to the Gemba—the place where value is created—to listen before acting. An overly implemental approach risks pushing top-down solutions without understanding the real problems.

Lean action: Practice Gemba walks, ask open-ended questions, and involve frontline employees in solution design.

4. Promotion vs. Prevention Mindsets – Striving for Excellence, Not Just Avoiding Failure

A promotion mindset seeks to win, improve, and innovate—perfect for Lean, where the goal is to deliver better value continuously. A prevention mindset focuses mainly on avoiding problems, which can lead to stagnation.

Lean action: Encourage teams to run small, low-risk experiments to explore better ways of working, rather than simply preventing errors.

Lean Leadership: Harnessing Agility and a Lean Mindset

Today’s leaders must be agile, receptive to feedback, and committed to learning. Lean Thinking gives them the tools to turn that mindset into measurable business results by:

  • Reducing waste to free up capacity
  • Increasing value delivery for customers
  • Building a culture where improvement is part of everyone’s job

The combination of a growth mindset and Lean Thinking is a powerful formula: one provides the belief in potential, and the other provides the method to realize it.

In short: Lean gives you the how, and a growth mindset gives you the will. Together, they help your business continuously improve, adapt, and win.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Monday, October 13, 2025

The Power of Discovery: Lessons from Columbus Day


On the second Monday of every October, the United States observes Columbus Day — a holiday rooted in the voyages of Christopher Columbus, who in 1492 set out across an uncharted ocean and sighted land after two grueling months at sea. While his journey is remembered in classrooms as the one that “sailed the ocean blue” aboard the Niña, Pinta, and Santa María, the real legacy worth honoring lies in the spirit of discovery his voyage represents.

From its earliest observances, Columbus Day was about more than the man himself. In October 1892, President Benjamin Harrison proclaimed the first “Discovery Day,” asking Americans to “cease from toil” and honor both the achievements of exploration and the opportunities it had unlocked. The celebrations of that era recognized a uniquely American spirit — one of risk-taking, pioneerism, and relentless improvement. It was the same mindset that transformed a sparsely populated wilderness into a thriving, ever-evolving nation.

That spirit is just as relevant today in our workplaces as it was on the high seas in 1492. In Lean manufacturing, discovery is the act of finding something new — or uncovering something long present but previously unseen. It is about asking questions that challenge the status quo, provoke thought, and push us deeper into the “why” behind our processes.

Thinking is not driven by answers but by questions. Answers often bring thought to a halt; only when an answer sparks another question does true thinking — and improvement — continue. Deep, purposeful questions help us navigate complexity, clarify our objectives, and evaluate the quality of the information we rely on.

In this way, Lean improvement mirrors exploration:

  • Questioning is our compass. Asking “Why?” multiple times digs to the root causes of problems.
  • Risk-taking fuels progress. Just as Columbus ventured into the unknown, organizations must step beyond familiar routines to uncover better ways of working.
  • Learning drives advancement. Every discovery should lead to shared knowledge, so improvements ripple across the organization.

Without questioning, there is no discovery. Without discovery, there is no improvement.

So, this Columbus Day, consider honoring that legacy not just with a history lesson, but by reigniting the spirit of exploration in your own sphere. Take the time to discover — your company, your employees, your processes, your problems, and your customers. Embrace curiosity. Encourage bold questions. Chart the course for improvements that will move you, your team, and your organization forward.

After all, Lean success, like great voyages, begins with the courage to set sail toward the unknown.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Friday, October 10, 2025

Lean Quote: Making Doing the Right Things Easy

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.


"Create an environment where doing the right thing is as easy as possible.  —  James Clear

On the shop floor, every shift is a mix of moving parts—machines, people, schedules, and unexpected problems. It’s tempting to push harder and faster. But if we’re not focused on the right work, speed won’t help. It’s like running full speed in the wrong direction.

Efficiency vs. Effectiveness

  • Efficiency = Doing things right (tightening bolts quickly).
  • Effectiveness = Doing the right things (tightening the bolts that keep the product safe).

Both matter—but effectiveness comes first. Leadership’s role is to make sure every operator knows exactly what the “right things” are, and that it’s the easy choice to do them.

On the Shop Floor, “Easy” Means:

  • The correct tool is within arm’s reach—no hunting for it.
  • The standard work instructions are right where you need them, clear and visual.
  • Quality checks are built into the process, not tacked on at the end.
  • Communication flows quickly from leadership to operators and back again.

Why It Matters
If the environment makes the right action harder than the shortcut, people will take the shortcut. That’s not a training problem—it’s a design problem. Leaders create the system; the system shapes behavior.

From Crisis Mode to Control Mode
When we live in crisis management—jumping from fire to fire—quality drops, deadlines slip, and stress spikes.
When we shift to a proactive mode:

  1. Plan first – Identify the top 20% of activities that give 80% of the results.
  2. Communicate clearly – Everyone knows the day’s priorities before machines start running.
  3. Make it visible – Use boards, signals, and metrics so progress is obvious.
  4. Track and adjust – Review results at the end of shift and fix roadblocks fast.

The Leadership Connection
Leaders aren’t just decision-makers—they’re environment designers. Every barrier removed, every visual cue added, every tool placed correctly is leadership in action. When the right thing is the path of least resistance, people do it naturally.

Bottom Line
High-payoff activities drive focus. Focus drives performance. Performance drives results. And the fastest way to improve all three is to design a workplace where doing the right thing is the easiest thing.


Wednesday, October 8, 2025

Highlights from the 2025 New England Lean Summit


This past week I attend the 2025 New England Lean Summit, held October 1–2 in Cromwell, CT. This intimate conference brought together Lean practitioners, executives, and change leaders from across the region to share practical strategies, inspiring stories, and hard-won lessons from the front lines of continuous improvement. Organized by New England LeanConsulting and Paul Critchley, the Summit offered two packed days of workshops, keynotes, and case studies designed to help organizations align culture, leadership, and improvement efforts.

Day 1: Setting the Stage

The first day kicked off with a deep-dive workshop by John Dyer focused on combining process improvement, leadership engagement, and cultural development.

Other standout sessions included:

  • Better, Not Bitter: Practical Tips for True Engagement — lessons from Joan Perreault and Kelley Watts on coaching frontline improvement teams with 12 tips for true engament.
  • Navigating Resistance: The Human Side of Change – led by April Thomas, equipping leaders to address the human side of change with empathy.

At midday, Colleen DelVecchio delivered an inspiring keynote, “Great Leaders Eat Lunch,” which highlighted the importance of leaders modeling the behaviors and values you seek and how creating a culture of wellbeing prevents burnout.

Day 2: From Culture to Action

Day two opened with Scott Gauvin’s keynote, “The Half of Lean You’ve Been Sleeping On – and Why It’s Time to Wake Up!” reminding attendees that sustainable performance depends more on people than on tools alone. This provocative talk suggested that culture (vs. tools) is often the roadblock to sustainable performance. Scott also shared the Respect for People Roadmap, which provides practical steps to embed respect into daily leadership behaviors.

I was honored to present “Lean Transformation Steps for Operational Excellence,” where I outlined a clear pathway for organizations seeking systemic change. My session emphasized the importance of starting with purpose, building leadership alignment, and engaging people at every level to drive transformation. I also shared practical tools for creating visibility of progress, sustaining momentum, and embedding Lean behaviors into organizational DNA. Attendees walked away with actionable steps to bridge strategy and daily execution while strengthening respect for people throughout the journey.

Other highlights included:

  • GKN’s “Brilliant Basics” Deployment – Find it, Fix it, Improve it! — a case study presented by Tiedah Evans from GKN Aerospace on driving continuous improvement across the organization via basic problem-solving.
  • Leading with Purpose: Merging Lean Principles, Self Awareness & Employee Engagement — Sandi Mauro integrating strategy and improvement work through logic models to maintain coherence and measurable impact.

The Summit closed with a lively Lean Leaders panel discussion challenging attendees to rethink how they approach Lean implementation and resistance.

Major Themes & Takeaways

Several clear themes emerged across the two days:

  1. Culture and Respect for People are Central. Lean success depends on building trust, psychological safety, and authentic engagement—not just applying tools.
  2. Change is Human, Not Just Technical. Leaders must recognize emotional responses to change and lead with compassion.
  3. Strategy and Daily Improvement Must Connect. Frameworks like charters and logic models help ensure alignment from the top floor to the shop floor.
  4. Practical Skills Drive Impact. Kaizens, key performance measures, and real-world examples provided actionable insights attendees can take home.
  5. Leadership is the Linchpin. Leaders at every level set the tone, provide recognition, and ensure purpose translates into performance.

Final Thoughts

The 2025 New England Lean Summit reinforced that Lean is not a set of tools—it’s a way of thinking and leading. From cultural change to operational excellence, the sessions highlighted both the challenges and opportunities in making Lean a sustainable advantage.

As a presenter, I was inspired by the energy and commitment of attendees and look forward to continuing the conversation on how leaders can drive transformation with purpose, respect, and alignment. If you weren’t able to join us this year, I highly encourage you to attend the Summit next year—you’ll leave with new insights, practical tools, and a stronger Lean community.

Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare

Monday, October 6, 2025

Celebrating National Manufacturing Week: Advancing Lean and Inspiring Future Makers


Each year, National Manufacturing Week provides an important opportunity to celebrate the contributions of manufacturers, highlight the value of modern manufacturing careers, and inspire the next generation of makers. As we recognize the essential role manufacturing plays in our economy and communities, it’s also a time to reflect on how lean principles help drive continuous improvement, innovation, and sustainability across the industry.

Why Lean Belongs at the Heart of National Manufacturing Week

Lean manufacturing is about more than eliminating waste—it’s about creating value, engaging people, and building a culture of problem-solving. During National Manufacturing Week, manufacturers can showcase how lean practices such as standard work, visual management, and respect for people make workplaces safer, more efficient, and more rewarding. These practices don’t just improve processes; they also empower employees and strengthen the long-term competitiveness of our organizations.

Key Activities to Celebrate and Promote Manufacturing Careers

National Manufacturing Week is not only a celebration but also a chance to inspire interest in manufacturing pathways. Here are some impactful activities for organizations and communities:

  • Plant Tours & Open Houses – Invite students, educators, and community members to experience modern manufacturing firsthand. Highlight lean practices in action to show how teams solve problems and create value.
  • Lean Demonstrations & Workshops – Offer hands-on simulations or kaizen events to teach participants about continuous improvement and the power of small changes.
  • Career Panels & Mentorship – Connect current professionals with the next generation by sharing diverse career stories and growth opportunities in manufacturing.
  • Showcasing Innovation – Use National Manufacturing Week to spotlight lean-driven innovations, sustainability initiatives, and digital transformation.
  • Employee Recognition – Celebrate the people who make manufacturing possible. Recognize teams who embody lean values like respect, collaboration, and continuous learning.

Building the Future Together

National Manufacturing Week is a reminder that manufacturing is not just about making products—it’s about making progress. By integrating lean thinking into the celebration, we not only honor the industry’s past achievements but also inspire the next generation to build a future where manufacturing is smarter, more sustainable, and people-centered.

Call to Action: As you celebrate National Manufacturing Week, take the opportunity to share your lean journey with others—whether that’s through a plant tour, a workshop, or simply recognizing the people behind the process. By opening the doors of manufacturing and showcasing the power of lean, we can engage new talent, strengthen our communities, and secure the future of this vital industry.


Subscribe to my feed Subscribe via Email LinkedIn Group Facebook Page @TimALeanJourney YouTube Channel SlideShare