Gemba Academy Podcast: Lean Manufacturing | Lean Office | Six Sigma | Toyota Kata | Productivity | Leadership

This week's guest is Radek Pietruszewski. To help fight COVID-19 in Poland, Radek and his software engineering colleagues figured out how to quickly manufacture thousands of face shields. He and Ron discussed the details of this impressive project. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  How things are going in Poland as far as COVID-19 (4:42) Radek's background and how he got involved in face shield production (5:43) What die cutting looks like (9:17) Where they got the raw materials from (10:46) Where the face masks are going (14:07) The timeline (16:03) How continuous improvement played a role (18:03) The cycle times for the individual processes (22:28) How they dealt with packaging and shipping (24:08) What production is like now (27:32) What Radek learned through this experience (29:15) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Radek's Podcast Radek

This week's guest is Jeff Kaas. Jeff explained how Kaas Tailored went from making furniture to making PPE in response to COVID-19. Jeff also shared some of the mistakes they've made, including reverting to batch production.  A MP3 audio version of this episode is available for download here. In this episode you'll learn:  About Kaas Tailored (4:07) Their PPE initiatives (6:36) Overcoming their fear (8:55) What they started with (11:43) How the lean mindset helped Jeff and his team (14:58) What didn't work (18:57) Why we revert to bad habits (19:55) What they've learned and what they would do differently (25:57) Manufacturing face shields (32:59) Their production mix (35:03) The true power of lean (37:44) About their waste tours (39:41) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com GA 211 | How to Navigate a Kaizen Journey with Jeff Kaas GA 268 | Breaking Down the Seven Wastes with Jeff Kaas Kaas Tailored Kaas T

This week's guest is James Newell. Ron and James explored the ways James has tailored the kata model to better suit different teams and industries. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires James (2:50) James's background (4:01) How James is adapting the improvement and coaching katas (7:49) Where James started (12:46) The German influence (14:41) Being open-minded (18:28) The importance of adapting kata (22:16) James's final words of wisdom (27:41) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com GA 224 | How to Apply Lean in Different Countries with James Newell James on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTunes account and smartphone. The easiest way for iPhone users t

This week's guest is Rodrigo Picoli. Ron and Rodrigo discussed the future of lean, the concept of the "beginner's mind," and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Rodrigo (4:09) His thoughts on Industry 4.0 (5:01) Rodrigo's background (7:02) The office in Brazil vs. Germany (9:35) Where America fits in (11:01) The role CI plays in new realities (12:36) The Japanese word "shoshin" (17:49) About the marshmallow challenge (22:14) Sustaining the changes (24:44) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Rodrigo on LinkedIn Rodrigo on Twitter The Future of Employment The Marshmallow Challenge Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTunes account and smartphone. The ea

This week's guest is Jaclyn Harder. Ron and Jaclyn discussed how lean applies to practicing law, as well as the power of taking action. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The words that inspire Jaclyn (2:48) Jaclyn's background (4:56) Where Jaclyn is now (9:27) How lean adds value in the legal profession (16:43) The power of jumping in and "doing" (20:33) Remembering the people who do the work (23:10) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Jaclyn on LinkedIn Women in Lean on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTunes account and smartphone. The easiest way for iPhone users to listen to the show is via the free, and incredible, Podcast app.  NEW! You can now follow the podcast on Spo

This week's guest is Audie Penn. Ron and Audie talked about the ways that lean can be used to help teams solve unique problems. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Audie (2:40) Audie's background (3:13) The power of lean (5:29) A defect Audie was seeing and how he approached it (7:33) Seeking out root causes (9:49) The tools Audie uses (11:18) The negative impact of expertise (16:03) Implementing countermeasures (22:08) What's missing (29:17) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Audie on LinkedIn Audie's Website Faro Partners The Fifth Discipline Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTunes account and smartphone. The easiest way for iPhone users to listen to

This week's guest is Calvin Williams. Ron and Calvin discussed leadership standard work and how continuous improvement could be used to navigate the global COVID-19 pandemic. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  A quote that inspires Calvin (3:30) How Calvin got into continuous improvement (4:53) The story behind Impruver (6:21) What leadership standard work means to Calvin (7:15) How this aligns with Hoshin Kanri (9:57) A case study (11:48) The need for experimentation (19:09) The potential benefits of using leader standard work at the national level (23:29) The importance of adaptability (30:01) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Calvin on LinkedIn Impruver Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be download

This week's guest is Karen Gaudet. Before becoming Team Leader of Operations and Personnel at LEI, she worked for Starbucks, and she shared the story of their powerful lean transformation with us. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Karen (3:09) Karen's background (4:36) Defining a leader's value (7:01) Leadership and personal growth (7:54) Standardization and respect for people (9:40) Navigating change management (13:47) About the leader led business transformation (15:24) What inspired Karen's book Steady Work (18:17) The relationship between best practices and best thinking (21:11) Advice for anyone struggling right now (25:18) What LEI is up to (28:31) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Steady Work LEI #LeanCommunity on Slack Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podc

This week we're sharing the audio of a webinar by Sam MacPherson. Sam discussed leading and communicating during a crisis, preparing for a crisis, applying SMED in a crisis, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  About Sam (2:10) Accepting a level of risk (4:14) A Black Swan event (5:33) A Grey Rhino event (8:42) Holding leaders accountable (13:14) Lean problem solving (15:23) Using a MECE analysis (16:42) All about a pace plan (27:59) How the different colored teams function (31:22) Using a SMED approach (40:41) Leading during the crisis (42:47) When to use and not use email to communicate (46:26) Avoiding analysis paralysis (49:03) Creating your war story after the crisis (54:42) Planning for White Swan events (57:39) Involving frontline/shop floor employees (58:59) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Subscribe & Never Miss New E

This week we're sharing the audio of a presentation on coaching, leader standard work, and uncertainty by our own Steve Kane. Steve's advice on uncertainty is particularly relevant to today. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The feeling of uncertainty (1:22) The role of routine (3:13) What uncertainty leads to (7:01) How this relates to coaching and leader standard work (9:57) The Self Journal (14:07) The role of the coach (18:01) The value of this model (19:53) Why you should "remain quiet" (22:22) Things to think about as we proceed into the unknown (24:04) Monitoring leader standard work (25:53) Planning your work, working your plan (28:37) What Gemba Academy offers (32:15) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Patrick Adams Consulting Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be s

This week's guest is Jamie Flinchbaugh. Ron and Jamie discussed the important role of trust in continuous improvement, and reviewed the 4Cs of Trust. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Jamie (5:27) Why Jamie is so passionate about trust (13:31) His approach (15:01) The sequence of the 4Cs (17:56) The demonstration of care (18:33) Communication of context (19:13) The possibility of over-communicating (23:02) Competence to deliver on the promise (24:25) What happens if we're lacking competence (26:01) Consistency of action (29:42) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Jamie's Website Is Trust Essential for Lean Success? The 4Cs of Trust Video Jamie on LinkedIn The Hitchhiker's Guide to Lean GA 016 | Developing Lean Leaders GA 083 | Getting the Board on Board with Lean Utilizing the 4Cs of Trust in Uncertain Times

This week's guest is Balaji Chandrasekar. Ron and Balaji reviewed the pillars of TPM, the challenges involved, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Balaji (3:11) Balaji's background (3:55) About TPM, or Total Productive Maintenance (5:07) Some of the challenges of implementing TPM (6:45) How the challenges are unique to TPM (10:03) What tools they leverage (11:09) The eight pillars of TPM (12:48) About OEE (18:20) Tracking OEE (20:40) Measuring maturity with TPM (22:16) Balaji's final words of wisdom (24:56) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com TPM Total Productive Maintenance New Implementation Program in Fabrication and Assembly Industries TPM in Process Industries Balaji on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on

This week's guest is Tracy Defoe. Ron and Tracy discussed why people practice Toyota Kata and continuous improvement in secret, and why it's problematic. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Tracy (3:46) Tracy's background (5:27) About practicing kata in secret (9:28) The root cause (16:24) The role of compassion (20:25) The way to learn kata (23:02) The pride and ego in continuous improvement (26:06) The DIY side (28:22) About the kata dojo (30:03) Tracy's advice on participating (35:54) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com The Learning Factor/Kata Geek Tracy on Twitter Tracy on LinkedIn Gemba Academy Toyota Kata Resources Peak Practice Perfect Kata Dojo Kata Europe KataCon Europe Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTun

Today we're releasing a special episode on the COVID-19 virus. Mark Graban, Dr. Greg Jacobson, and Dr. Mason Mileur recorded a webinar answering some commonly asked questions about this global pandemic, and what we can do to stay safe and help out.  A MP3 audio version of this episode is available for download here. Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com The Webinar on YouTube KaiNexus' Response to COVID-19 What You Can Do to Save People TODAY [COVID-19] COVID-19: What the Heck Does Exponential Mean?  Why the Public & Healthcare Response to COVID-19 Has Me Fuming Mark Graban's Lean Blog Stay at Home: A COVID-19 Message from an E.R. Physician, Greg Jacobson, M.D. Why These Doctors Say Staying Home is a Matter of Life and Death One Point Lesson: How to Wash Your Hands TWI Job Instruction Hand Washing Training Did You Find Yourself Working from Home All the Sudden? What is Exponential Growth and Why Should You Care?

This week's guest is Hal Macomber. Ron and Hal discussed the lean construction movement, the Last Planner System, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Hal (2:43) Hal's background (5:29) How lean was introduced to construction (9:51) The Last Planner System (13:57) Some of the key lean tenets (15:30) About Gemba Academy's new building (19:55) The role of Respect for People (23:29) Who is driving the change (30:04) The improvement to safety (31:48) Some of the challenges they're facing (35:14) The future and kaizen (40:37) Advice for those interested in lean construction (48:23) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Lean Construction Institute This Is Lean Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber

This week's guest is Brad Miller. Ron and Brad discussed how motivation factors into continuous improvement, and a modern motivation framework that could be useful to managers. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  Brad's background (2:51) The importance of an academic background (4:34) His favorite quote (6:05) The concept of motivation as it relates to continuous improvement (8:46) Getting to the goal (15:09) Dealing with uncertainty (16:21) Where training comes in (18:02) What people believe about the activity (20:17) How psychological safety plays into motivation (23:07) How mastery, autonomy, and purpose fit into Brad's framework (26:03) Another example (32:02) Exposing people to a better world (34:51) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Brad on LinkedIn Brad on Twitter Brad on YouTube Drive by Dan Pink The Fearless Organization M

This week's guest is Pete Kuehn. Ron and Pete discussed Pete's lean journey, including the effect lean has had on his personal life. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Pete (2:03) Pete's background (2:58) How Pete got into continuous improvement (4:38) The lessons he learned growing up (5:48) Why companies go lean (10:46) How lean affected his relationship with his wife (13:13) Building trust (15:46) Showing respect (17:57) Pete's 9/11 story (26:13) Some of Pete's favorite books (28:10) Pete's advice for those who are struggling (29:16) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com The Toyota Way The Goal Pete on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all new episodes will be downloaded to your iTune

This week's guest is Andy Reith. Ron and Andy discussed working at Toyota, the challenges small businesses face, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Andy (2:32) Andy's background (3:18) What Andy learned from working at Toyota (5:16) What Respect for People means to Andy (6:56) How Andy learned some of the lean tools (8:38) What Andy is up to these days (10:15) The challenges small businesses face (11:14) About Origin Maine (12:33) Some of the improvements Andy has seen (15:25) Andy's observations on strategy at small manufacturers (18:49) About his own andon system (24:07) Andy's advice (27:24) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Andy's Website Andy on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a

This week's guest is Lauren Hisey. Ron and Lauren talked all about automation and artificial intelligence, what the future holds as far as continuous improvement goes, and more. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  Lauren's favorite quote (2:23) Lauren's background (2:34) What AI entails and how it can be leveraged in continuous improvement (4:35) How organizations can become rigid (7:42) How to fix it (9:04) Addressing fears related to AI (10:23) Examples of leveraging AI (12:37) Another example (16:35) How AI can fall short (18:40) Advice on getting started with AI (20:09) Advice for future generations (21:45) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Lauren's Website  Lauren on LinkedIn Subscribe & Never Miss New Episodes! Click to Subscribe in iTunes If you enjoyed this podcast please be sure to subscribe on iTunes. Once you're a subscriber all

This week's guest is Karyn Ross. Ron and Karyn talked all about practicing kindness, why it's important, and how it's relevant to continuous improvement. A MP3 audio version of this episode is available for download here. In this episode you'll learn:  The quote that inspires Karyn (3:01) What kindness has to do with lean (4:34) How to be kind when it's difficult (7:30) How Karyn makes time for everything (11:40) The relationship between kindness and psychological safety (15:59) Ron's personal anecdote about kindness (18:57) How our hectic schedules affect our ability to be kind (25:34) Habits as they relate to kindness (28:18) An example (31:20) Karyn's final words of wisdom/kindness (36:24) Podcast Resources Right Click to Download this Podcast as an MP3 Download a Free Audio Book at Audible.com Tiny Habits by BJ Fogg Atomic Habits by James Clear The Fearless Organization by Amy Edmondson Love and Kindness Project Foundation Karyn's Website Karyn on Twitter Karyn on