Popular Posts
Toyota’s 1992 View: Standardized Work and Kaizen Are Two Sides of the Same Coin When Standard Work Isn’t Followed, Your Reaction Is the Real Standard What the First Twelve Years of Writing About Sports Taught Me About Leadership Four Headers, Zero Metrics: An Empty Huddle Board in the ICU Hallway A Locked Complaint Box in Greece: Learning From Customer Complaints, or Just Bureaucracy? If This Were Assembly Line Medicine, You Could Stop the Line Workplace Deaths by Age: Why Counts and Rates Tell Different Stories Do 90% of Lean Transformations Really Fail? I Went Looking for the Number
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Hyundai’s Humanoid Robots, GM Layoffs, Jim Farley’s Ford Quality Turnaround, and Toyota Kaizen for Coffee Farmers

ByMark Graban July 31, 2026 Comment (0) 8170
Formerly known as “Lean Whiskey” Listen: In Season 2, Episode 9, Mark Graban and Jamie...
Corkboard covered in pinned papers and red yarn, every strand converging on one small index card at the center

Do 90% of Lean Transformations Really Fail? I Went Looking for the Number

ByMark Graban July 30, 2026 Comment (1) 135
Composite blog cover image showing four factory workers of different ages in safety gear standing in an industrial workplace, above two side-by-side charts comparing workplace fatality counts and rates by age; the left chart suggests higher total deaths in middle age groups, while the right chart shows fatality rates rising sharply for older workers.

Workplace Deaths by Age: Why Counts and Rates Tell Different Stories

ByMark Graban July 29, 2026 Comment (0) 136
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A Locked Complaint Box in Greece: Learning From Customer Complaints, or Just Bureaucracy?

ByMark Graban July 28, 2026 Comment (0) 194

Mark Graban

Welcome to my blog!

Since 2005, LeanBlog.org has shared practical insights from real-world work in healthcare, manufacturing, and beyond.

Books Keynote Speaking Coaching / Advisory Podcasts
Books by Mark Graban on Lean, Leadership, and Learning (4)

Lean Blog Interviews Podcast

Deepening our Understanding of Lean Manufacturing and Respect for Humanity with Norman Bodek

Deepening our Understanding of Lean Manufacturing and Respect for Humanity with Norman Bodek

ByMark Graban August 5, 2006 1650
Here is the second LeanBlog Podcast, featuring author and consultant Norman Bodek, President of PCS Press. The first one can be found here and you can visit the main Podcast page, which includes...
Norm Bodek on the Power of Kaizen: Unlocking Employee Creativity and Continuous Improvement – LeanBlog Podcast #1

Norm Bodek on the Power of Kaizen: Unlocking Employee Creativity and Continuous Improvement – LeanBlog Podcast #1

ByMark Graban July 16, 2006 3775
In the first-ever Lean Blog Podcast, Mark Graban talks with Norm Bodek about quick and easy Kaizen and how it differs from large, event-based improvement efforts. Bodek explains how simple...

More Blog Posts

Mistake-Proofing at the Gas Pump: Why I Didn’t Forget My Credit Card

Mistake-Proofing at the Gas Pump: Why I Didn’t Forget My Credit Card

Mark GrabanByMark Graban April 10, 2023 2767
Mistake-proofing shows up in everyday life more often than we realize–and a recent trip to the gas station reminded me why it matters. Chapter 4 of my book The Mistakes That Make Us: Cultivating...

Ryan McCormack’s Operational Excellence Mixtape: April 7th, 2023

Ryan McCormackByRyan McCormack April 7, 2023 1260

“The Mistakes That Make Us” — My Manuscript is Done! Some Backstory and What Comes Next

Mark GrabanByMark Graban April 5, 2023 1662

How to Create a Continuous Improvement Culture by Closing the GAPS — with Katie Anderson [Recording]

Mark GrabanByMark Graban April 4, 2023 3951

Wishing Tom Peters a Happy Retirement

Mark GrabanByMark Graban April 3, 2023 1759

Webinars

karen martin ask the expert webinar kainexus

Ask Karen Martin Anything on Operational Excellence: A KaiNexus Webinar

March 5, 2026
Karen Martin is one of those people I've been lucky to know and learn from for a long time. She's...
1. Professor with glasses in front of EMS 20th anniversary logo and KaiNexus logo on blue background.

Unlock the Power of Leadership: A Preview of the Electrolux Manufacturing System (EMS) Webinar

December 4, 2025
KaiNexus recently hosted a webinar I was especially looking forward to: “Unlock the Power of...
Breaking Through Cultural Friction: Respect for People and Sustainable Performance

Breaking Through Cultural Friction: Respect for People and Sustainable Performance

June 9, 2025
When organizations struggle to sustain Lean transformation, people often look first at tools...
Driving a Culture of Patient Safety: Lessons for Healthcare and Beyond

Driving a Culture of Patient Safety: Lessons for Healthcare and Beyond

April 28, 2025
Recently, I had the pleasure of moderating a webinar titled “Driving a Culture of Transforming...
Why Lean Fails Without Psychological Safety

Why Lean Fails Without Psychological Safety

April 16, 2025
TL;DR: Lean tools don't fail because people resist change–they fail because people don't feel...
Preview: Driving a Culture of Accountability – Transforming Patient Safety with KaiNexus (Webinar, April 15)

Preview: Driving a Culture of Accountability – Transforming Patient Safety with KaiNexus (Webinar, April 15)

April 8, 2025
One of the most powerful elements of continuous improvement is the ability to learn from each other...
My Upcoming Webinar on Mistake-Proofing Across Industries

My Upcoming Webinar on Mistake-Proofing Across Industries

February 3, 2025
I'm excited to be presenting this webinar on February 12th at 1 pm ET as part of the KaiNexus...
Top 5 Takeaways from my KaiNexus Webinar: Psychological Safety as a Precondition for Continuous Improvement

Top 5 Takeaways from my KaiNexus Webinar: Psychological Safety as a Precondition for Continuous Improvement

January 8, 2025
TL;DR: Psychological safety isn't optional for continuous improvement. This KaiNexus webinar...
Creating Leader Standard Work (LSW) Across a Distributed Business Model — Webinar Preview

Creating Leader Standard Work (LSW) Across a Distributed Business Model — Webinar Preview

November 7, 2024
I'm happy to be hosting and moderating this webinar that will be presented by Brent Loescher, a...
Embedding Change Management into your Continuous Improvement Initiatives – Webinar Preview

Embedding Change Management into your Continuous Improvement Initiatives – Webinar Preview

September 25, 2024
I'm happy to be hosting and moderating this webinar that will be presented by Melissa Sherman, a...
View Our “Ask Us Anything” Event on Psychological Safety and Lean

View Our “Ask Us Anything” Event on Psychological Safety and Lean

August 20, 2024
Psychological safety is often described as “feeling safe to speak up.” In Lean...
From Strategy to Execution: Webinar with Karen Friedenberg

From Strategy to Execution: Webinar with Karen Friedenberg

July 17, 2024
Are you looking to transform your business strategy into actionable results? Join us for our...

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Mark Graban on YouTube

Lionel Messi can appear to be standing around while everyone else is running. But that apparent inactivity can be highly efficient. He preserves energy, studies the field, finds space quietly, and becomes harder to mark—then accelerates when the opportunity appears. Jamie Flinchbaugh explains why this works for certain intelligent players in specific roles, but not for an entire team. Across the full match, effort still matters—and teams that cover more ground often gain an advantage. From Episode 9 of Lean Coffee Talk with Mark Graban and Jamie Flinchbaugh. #Shorts #LionelMessi #Soccer #Football #Haaland #LeanThinking #Efficiency
Why Messi’s “Lazy” Walking Is Actually Strategic
Some people avoid mistakes so completely they avoid doing anything meaningful at all. Boo Boucousis connects two data points -- low workplace engagement and rising burnout -- to explain why busyness often masks disconnection, and why effort alone isn't enough without results. Watch the full episode: https://youtu.be/K2qUVIkn_vc Subscribe for more conversations on leadership, psychological safety, and learning without blame.
The Real Reason People Avoid Mistakes at Work
GM laid off more than 1,000 workers at its Factory Zero plant while adding 50 new robots. The headline practically writes itself: robots replaced the workers. But the cause-and-effect story is not that simple. The layoffs were tied to lower-than-expected EV demand, while the robot purchase was a separate investment. Both facts were true. The timing—and the optics—were terrible. From Episode 9 of Lean Coffee Talk with Mark Graban and Jamie Flinchbaugh. #Shorts #Automation #Robotics #GeneralMotors #Manufacturing #Lean
GM Laid Off 1,000 Workers—and Added 50 Robots
Humanoid robots, GM and Hyundai layoffs, and Ford CEO Jim Farley's quality turnaround - plus Toyota's Kaizen work with coffee farmers in Thailand. Mark Graban and Jamie Flinchbaugh cover a lot of ground in episode 9. Topics this week: World Cup officiating and the line between precision and judgment (VAR, ABS challenges, the strike zone). Toyota's Kaizen partnership with coffee farmers in Thailand. Hyundai workers striking over Boston Dynamics' Atlas robots. GM's layoffs-plus-robots headline in Detroit. Ford's Jim Farley on Gemba, quality culture, and $5 billion in recall costs. Burger King's new "Your Way Champion" role and its quality turnaround ads. Timestamps: 0:00 Intro 0:23 World Cup recap: officiating, VAR, and the ABS challenge system 20:51 Coffee talk: dealer's choice and a Mason jar mishap 25:31 Toyota's Kaizen work with coffee farmers in Thailand 37:13 Hyundai workers strike over humanoid robots (Boston Dynamics) 51:14 GM lays off 1,000 workers, adds 50 robots 56:57 Ford's Jim Farley on Gemba and quality culture 1:20:40 Burger King's "Your Way Champion" quality role 1:33:18 Cultural picks: Ted Lasso season 4, forgotten board games 1:37:25 Wrap up Subscribe for more conversations on Lean thinking, quality, and leadership. #LeanManufacturing #Kaizen #ContinuousImprovement #Toyota #QualityCulture #Robotics #Automation #FordMotorCompany #LeanLeadership #LeanCoffeeTalk
Robots vs Jobs, Ford's Quality Fix | Lean Coffee Talk 9, with Mark Graban and Jamie Flinchbaugh
Christian "Boo" Boucousis breaks down the difference between "perfect" and "flawless" -- and why chasing perfection means trying to control things you never could in the first place. He explains why the brain defaults to this narrative anyway, and what it costs leaders who don't catch it. Watch the full episode: https://youtu.be/K2qUVIkn_vc Subscribe for more conversations on leadership, psychological safety, and learning without blame:
Perfect vs. Flawless: The Difference That Changes How You Lead
Asked for his favorite mistake, Boo Boucousis points out that fighter pilots don't actually have the concept. Every mission produces either what you set out to achieve, or "other things" -- and Boo traces how school conditions us to fear the word "mistake" long before we ever set foot in a workplace. Watch the full episode: https://youtu.be/K2qUVIkn_vc Subscribe for more conversations on leadership, psychological safety, and learning without blame.
His Favorite Mistake Is a Trick Question -- Fighter Pilots Don't Have the Word
Leaders often say they want the bad news fast -- but punish people for actually bringing it. Boo Boucousis, former fighter pilot and CEO of Afterburner, explains why sweeping a mistake under the carpet as a leader teaches everyone else to do the same, and how the debrief habit that fighter pilots use can cut the emotional residue and reset the room. Watch the full episode: https://youtu.be/K2qUVIkn_vc Subscribe for more conversations on leadership, psychological safety, and learning without blame.
Why Sweeping Mistakes Under the Carpet Costs Leaders the Big Picture
In fighter jet aviation, errors can be fatal -- so the systems built around learning from them have to work. My guest is Christian "Boo" Boucousis, a former Australian fighter pilot and CEO of Afterburner, a leadership firm that has spent 30 years translating combat aviation discipline into frameworks for business. Boo explains why fighter pilots don't use the word "mistake" at all -- they debrief "other things that happened" -- and how that single shift in language changes what people are willing to admit, and how fast a team can learn. Episode page with links and more http://markgraban.com/mistake359 We get into the ORCA debrief method (Objective, Result, Cause, Action), why even the most senior pilots in the room are expected to raise their hand first, and why Boo now teaches leaders to aim for "flawless" instead of "perfect" -- a distinction that changes how you handle things you can't control. What you'll learn: 🔵 Why fighter pilot culture has no concept of "mistake," only data to debrief 🔵 The ORCA method: Objective, Result, Cause, Action 🔵 Why senior leaders admitting error first is what makes psychological safety real, not aspirational 🔵 The difference between "perfect" and "flawless" -- and why one leads to burnout 🔵 Why 86% of leaders may have undiagnosed perfectionism, and how it shows up as control 🔵 How "to-do" lists differ from "achieve" lists, and why the switch matters 🔵 Why slowing down intentionally is often the fastest way through ambiguity Chapters 🔵 00:00 Introduction: fighter pilots and psychological safety 🔵 01:57 Boo's favorite mistake -- and why fighter pilots don't use that word 🔵 05:13 The mission commander debrief: senior leaders admit error first 🔵 09:44 The ORCA method explained 🔵 17:04 Leaving the military: why business commitments felt different 🔵 21:10 Reprogramming leaders who were taught to fear mistakes 🔵 31:30 Speed vs. velocity, and starting meetings at the finish line 🔵 44:16 Perfect vs. flawless: the healthier standard for leaders About Christian "Boo" Boucousis: Boo is a former Royal Australian Air Force fighter pilot and the CEO of Afterburner, which has worked with more than 3,500 organizations, including two Super Bowl-winning NFL teams. He is the author of The Afterburner Advantage and the upcoming Flawless Leadership.
The Fighter Pilot Debrief Method That Kills Blame at Work | Christian "Boo" Boucousis
A young fighter pilot watches three of the most senior leaders in the Air Force admit their own mistakes first, in front of everyone. Boo Boucousis, former fighter pilot and CEO of Afterburner, explains why that moment shaped how he thinks about psychological safety, and why the mistake itself matters less than the admission and what happens next. Watch the full episode: https://youtu.be/K2qUVIkn_vc Subscribe for more conversations on leadership, psychological safety, and learning without blame
The Debrief Where Three of the Air Force's Top Leaders Raised Their Hands
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