Lean Roundup #192 – May 2025

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

 

Psychological Safety: You get your say, not always your way. – Mark Graban explains that psychological safety doesn't mean consensus. It doesn't mean you'll get your way every time.

 

The Improvement Kata and DMAIC – Mark Rosenthal talks about the connection between the improvement kata and DMAIC principles.

 

Failure to Identify Risks - Alen Ganic explores three common categories of risk—technical, people, and timing—through examples that illustrate the importance of proactive risk management.

 

The 3 Levels of Lean Mistake-Proofing (Poka-Yoke): How to Prevent Defects and Boost Quality (Boston Edition) - Paul Critchley explores the three levels Lean mistake-proofing and how you can apply them to optimize your operations with a New England style example.

 

The Importance of Act in the PDCA – Christoph Roser says despite its apparent simplicity, there are many struggles involved with PDCA’s proper use and it seems that the Act part is especially challenging so he digs deeper into why and how to Act in the PDCA.

 

Stop Reacting to Red Light Metrics: Why ‘Two Reds in a Row’ Is a Misleading Rule of Thumb – Mark Graban writes about how people react to “red” data points in their workplace metrics, misleading rules of thumb, and why process behavior charts are more valid.

 

The Hardest Thing - Seeing What Is - Pascal Dennis talks about the cognitive biases that afflict human beings and hinder our ability to see.

 

The Control Tower – Learning to See What Is – Pascal Dennis talk about perhaps the most useful management system: the Control Tower (aka Big Room, Cockpit or ‘Obeya’).

 

Yokoten: Capturing and Sharing Best Practices - José R. Ferro explains that to accelerate learning and change, don’t copy blindly—observe, adapt, and apply with purpose and that’s where yokoten drives real transformation.

 

Executing Strategy through Daily Management  - Robson Gouveia and José R. Ferro explain how daily management closes the gap between strategy and execution by aligning daily work with strategic objectives, enabling real-time performance tracking, and fostering a culture of problem-solving.

 

Perspectives on People-Centric Improvement - Mark Reich highlights the essential role of people in driving lasting improvement. Drawing from Toyota’s principle of respect for people, contributors explore how activating, developing, and engaging employees unlocks true productivity and sustainable transformation across organizations.

 

A Free Resource for Leaders: The Mistake-Smart Leader’s Checklist – Mark Graban created a simple new resource from Singo Prize winning book The Mistakes That Make Us, that you can use as a team conversation prompt, a coaching framework, or a reminder on your office wall.

Lean Roundup #191 – April 2025

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

 

Fluctuations on Continuously Moving Assembly Lines 3—The Value of Team Leaders - Christoph Roser talks about one key tool for reducing fluctuations on Toyota assembly lines is the team leader, the frontline support for operators.

 

No Substitute for Experience – Bruce Hamilton shares a personal story illustrating the lesson for why there is no substitute for experience.

 

Fundamentals of OpEx/Lean, Part 1 – Pascal Dennis shares four levels of Visual Management, in order of increasing power.

 

Starting a Lean Transformation: Building a Team of ACEs - Tyson Heaton and Noel Jarin talk about how activating, cultivating, and elevating a team of ACEs can drive lasting performance gains across any operation.

 

Want to Improve Your Product Development? Prioritize Organizational Learning  - Steve Shoemaker discusses why product development excellence depends on stable, cross-functional teams and a culture that learns from both failure and success.

 

Solving the Productivity Paradox - Jacob Stoller shares how leaders can drive real gains—not by cutting people, but by engaging them in redesigning work.

 

Multi-level Visualization: Engage Everyone in Problem-Solving to Achieve Business Results - Michael Ballé shows how leaders can use visualization to align lean problem-solving with business results.

The Difference Between a Lean Leader and a Regular Leader - Alen Ganic gives insight into what you can do to become an excellent leader—what we call a Lean leader.

Leadership by Fear Doesn’t Work — And Never Really Did – Mark Graban dispels the myth that fear is a performance enhancer.

Lean Isn’t Just About Cost: Stop Putting a Stick in Your Own Bicycle Spokes – Mark Graban explain why we should not sabotage our own efforts, take the stick out of the wheel — and keep moving forward, together.

Lean Roundup #190 – March 2025

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

 

Toyota Raku: Respect for People, Comfort, Ease, & Ergonomics - Mark Graban shares his experience to a Toyota plant that focused on raku–making work easier, more comfortable, and more accessible for all team members–reinforces its deep commitment to respect for people.

 

If It’s Not Simple, It's… - Pascal Dennis says breakthrough should be as easy as continually making & easy quick experiments, most of them yielding a negative result.

 

How to Recognize and Remove Waste in Your Organization - Alen Ganic explains why learning to see waste is crucial for both individuals and businesses.

 

Legend – Bruce Hamilton shares the impact and learning from Dr. Shingo and his visit to Bruce’s Watertown, MA factory in 1989.

 

What if we could eliminate fear in the workplace? - Glenn Whitfield discusses the benefits of a workplace and what can be accomplished when we eliminate fear.

 

How to Grind Your Organization to a Standstill—Part 1 & Part 2 - Christoph Roser shares a sarcastic post on how to bring your organization to a standstill… not because he wants that, but so you can see what NOT to do to in order to improve your organization.

 

Has OpEx/Lean Gone Wrong? – Pascal Dennis says we must look outside the relatively predictable world of Operations, and into the volatile, uncertain, complex and ambiguous world of the customer.

 

How to Ensure Long-Term Sustainability of Operational Excellence Efforts - Daniell Yoon explores key strategies for ensuring the long-term sustainability of operational excellence initiatives.

 

In Order to Compete, You Need to Learn to Cooperate - Christopher R Chapman shares video regarding how the drive to compete adversarially has overtaken the ability to work cooperatively.

 

Hoshin Kanri as a Foundational Piece of a Lean Management System - Jeffrey Liker and John Shook explain that hoshin kanri is more than a strategic planning tool—it’s a dynamic, socio-technical process that aligns organizations at every level through shared purpose, problem-solving, and continuous learning.

 

Three Faces of Lean Management  - Jeffrey Liker urges the lean community to move beyond tools and templates because lasting transformation requires integrating lean’s technical, social, and scientific dimensions while developing people who can learn their way forward.

 

Why Great Leaders Share Responsibility Instead of Throwing Others Under the Bus - Mark Graban describes true leadership is about standing together, not standing apart when challenges arise.

Lean Roundup #189 – February 2025

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

 

Getting the Right Things Done in a Digital World – Pascal Dennis shares his learnings from Lean innovation and mindsets in Tech startups and what it means for progressive organizations around the world.

 

Where Should We Start With Lean? - Alen Ganic explains if you’re considering Lean for your organization, start by securing leadership buy-in and making sure everyone understands why it matters then Lean tools will help you solve real problems, sustain improvements, and drive meaningful change.

 

Why Is So Important for Managers to Listen! – Christoph Roser says listening to your operators and employees is an undervalued but very beneficial skill that will help you to improve your system.

 

All Unit Tests Passed – Christopher Chapman discusses an anti-pattern in software development that happens when automated tests are engineered to pass in spite of the product not working as the customer expects.

 

Assuming Your Team Doesn’t Care? Think Again. – Katie Anderson says it’s time to challenge your assumptions about your employees and examine how your limiting beliefs are leading to missed opportunities to build a more engaged and innovative team.

 

Building Operational Excellence Culture – Maggie Millard outlines the essential leadership behaviors for building and sustaining an operational excellence culture.

 

Whose Fault Is It Anyway? The Case for Learning Over Blaming – Mark Graban explains mistakes should lead us to reflection and positive change–it's about building trust, fostering innovation, and creating a workplace where people feel empowered to learn and grow.

 

How Internal Politics Kill Lean Transformations—And What to Do About It – Damon Baker talks about why organizations can’t get out of their own way—and what it takes to finally break free.

Lean Roundup #188 – January 2025

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

 

Starting the New Year with Global Leadership Resolutions: Building a Foundation of Psychological Safety – Mark Graban says if we aim to build a Lean culture, it must rest on a foundation of Psychological Safety where people generally feel safe speaking up about problems, sharing ideas, and experimenting without fear of retribution.

 

The Power of Visual Management – Transforming Workspaces and Mindsets – Alen Ganic explains visual management is more than just a tool—it’s a mindset; by making tasks and progress visible, we reduce waste, improve efficiency, and foster continuous improvement in both professional and personal environments.

 

Optimizing Continuous Quality Improvement: Essential Tools and Strategies for Success – Maggie Millard says organizations can reach their full potential in the pursuit of excellence through continuous quality improvement by embracing the principles and tools of incremental change, respect for people, clear goals, and structured methodologies,

 

Why Gemba Walks Matter & How to Make Them Work – Kade Johnson shares 11 steps you can take to ensure that your next Gemba walk is successful.

 

Kaizen: Hoshin Kanri, Bowler Charts, Action Plans, and More – Christoph Roser describes the big picture of kaizen improvement involving True North direction, overarching targets of hoshin kanri, practical problem solving, and action plans to make actual improvements.

 

Japan Study Trip Highlights: November 2024 – Katie Anderson shares another incredible immersive learning experience from 6^th cohort of the Japan Study leadership program from November 2024.

 

Steve Jobs on Quality and Juran – Christopher R Chapman shares video of the late, great Steve Jobs, where he was interviewed about the influence Dr. Joseph Juran had on his thinking about quality.

 

Building a Resilient Business with Hoshin Kanri and Problem Solving : A Conversation with Grand Rapids Chair CEO Geoff Miller – Geoff Miller and Mark Reich shares insights on building resilience through hoshin kanri and daily problem-solving to transform culture and performance.

 

Safety First: GE Aerospace’s Lynn Facility Demonstrates True Lean Leadership – Mark Graban shared GE Aerospace's Lynn, MA, facility which provided an inspiring example of what respecting people, empowering people, and ensuring their well-being while driving continuous improvement.

Lean Roundup #187 – December 2024

A selection of highlighted blog posts from Lean bloggers from the month of December 2024.  You can also view the previous monthly Lean Roundups here.  

 

WSJ Shows Us a Day in the Life of a Plant Manager — Including Lean Practices – Mark Graban discusses fascinating article about Whirlpool Plant Manage Day in the Life offering valuable insights for anyone interested in operational excellence, leadership, and Lean thinking.

 

Why We Need Visual Management… - Christoph Roser talks about the need to go out, understand your shop floor, see the problems, see the target situation, and create a way from the current situation to the target situation to do kaizen.

 

Whatare the biggest obstacles to an effective and sustained Lean initiative? – Michael Sinocchi asks author Bill Artzberger to share the biggest obstacles to an effective and sustained Lean initiative.

 

Year-End: Why Is Reflection So Difficult? – Pascal Dennis explains the steps to an effective year-end reflection activity.

 

Unlocking the Secret to Success: Managing for Daily Improvement (MDI) – Alen Ganic discusses the steps, best practices, and pitfalls to avoid implementing successful daily management meetings.

 

The Timeless Power of Gratitude – Ron Pereira discusses how gratitude transforms how we see the world and how to practice gratitude.

 

5 Whys: A Simple Tool for Root Cause Analysis and Goal Setting – Jeff Roussel talks about the versatility of repeatedly asking “why” to uncover root causes, address underlying issues, and even clarify goals.

 

Why Operators Need to Measure Their Own Data! – Christoph Roser explains why self-measurement of process-related data makes it so much more likely that the data is used for improvement.

 

Hoshin vs. Chaos – Jim Womack reflects on the Toyota hoshin process he observed in 2018 and how it has led them to design a portfolio of countermeasures to navigate the industry's current chaos.

 

Santa’s Hoshin Objectives: Driving Strategic Alignment at the North Pole – LEI shares Santa's hoshin objectives to improve how North Pole, Inc delivers happiness to children around the globe.

  

Lean Roundup #186 – November 2024

A selection of highlighted blog posts from Lean bloggers from the month of November 2024.  You can also view the previous monthly Lean Roundups here.  

 

Dark Lean - Christoph Roser explains in order to do good lean, we need to understand why some lean projects are bad 0r, in order for practitioners to reach the light side of lean, they need to understand more about “Dark Lean.”

 

Reflections on Deploying Improvement Strategies – Pascal Dennis shares his reflections on deploying improvement strategies.

 

Building Loyalty and Empowering Growth: How Lean Principles and Genuine Mentorship Drive Employee Retention – Alen Ganic shares the practices successful organizations have adopted that retain staff long-term focused on creating an inviting, flexible, and supportive work environment.

 

Consolation and Desolation: Lessons from St. Ignatius for Business Leaders – Ron Pereira explores how St. Ignatiusa 16th-century saint and founder of the Jesuits, advised navigating spiritual states, and how these lessons apply to the challenges and triumphs leaders face in the business world.

 

Corporate Bystanders: The Leaders Who are Just Along for the Ride – Damon Baker explains why we need to challenge the paradigm of corporate bystanders believing they’re along for a smooth ride, but the truth is, they’re dragging the company down because in the end, leadership isn’t about titles or perks; it’s about making a difference where it matters most.

 

Leadership Cheat Codes – Christopher Chapman shares five of the best cheat codes along with some short stories drawn from real experiences that help to set them in your mind, especially those who are on a path to leadership—although, they will benefit anyone to know.

 

Toyota Change Point Management: Henkaten – Christoph Roser explains Henkaten, often translated as “change point,” an approach by Toyota to deal with changes in their manufacturing system.

 

Introduction to Daily Management to Execute Strategy - Robson Gouveia and José R. Ferro provide a complete introduction to their new book “Daily Management to Execute Strategy.”

 

Hoshin Kanri Ensures Frontline Problem-Solving within Lean Management – Mark Reich explains how hoshin kanri links strategic goals with frontline problem-solving, creating a unified approach to continuous improvement and empowering teams at every organizational level.

 

The Value of Key Performance Indicators in a Lean Transformation - Ernie Richardson and Tracey Richardson share their thoughts on the two categories of key performance indicators (KPIs) in the workplace, how they can help you, and how to identify them.

 

Reflecting on my First Time Meeting Isao Yoshino in Japan — 2012 – Mark Graban reflects on his last trip to Japan and the lessons learned from Mr. Yoshino (subject of Katie's Shingo Award-winning book Learning to Lead, Leading to Learn) ahead of embarking on a new trip with Katie Anderson to Japan.