TL;DR: Understanding Variation by Donald J. Wheeler is the most influential book in my Lean journey. It taught me how to distinguish signal from noise in data, avoid overreacting to normal variation, and focus leaders on improving systems instead of…
tl;dr: Most “Lean Six Sigma” programs teach a thin layer of Lean tools on top of a heavily Six Sigma-centric curriculum. If you want real Lean thinking, culture, and leadership, this format rarely delivers it. I had a conversation recently…
Some of the best lessons I have ever learned for my career are from Donald Wheeler’s brilliant book Understanding Variation: The Key to Managing Chaos. One idea is that data without context is meaningless. The other is the application of…
Are We 84.7% Certain We’re in the 90th Percentile? Of course, hospitals should focus on patient satisfaction. That’s important but is often a vague and uncertain thing to measure. But, as Dr. Deming said: “The most important figures that one…
Mishandling Has Spiked Since Liquid Ban Reduced Carry-Ons – washingtonpost.com With the new security rules in August, the number of checked bags increased suddenly (including my own, until I changed my process to include leaving a bag of toiletries at…
TL;DR: The NHS backlog gets narrated one month at a time, and millions in bonus money ride on the moves. A Process Behavior Chart shows most movement is noise — and the trusts that stay on top are running structurally…
tl;dr: The “two consecutive reds” rule persists because reacting feels like leadership — but it generates wasted investigations, false success stories, and eroded trust. Process Behavior Charts tell you when variation actually means something changed. I’m writing about something that…
Are "visuals" and "visual management" the same thing? Are "visuals" always Lean, necessarily? In this post, I talk about the differences using an example from a hospital and my car's dashboard.
Scroll down for how to subscribe, transcript, and more My guest for Episode #491 of the Lean Blog Interviews Podcast is Sarah Tilkens, an experienced Lean Leader with a demonstrated history of working in construction and manufacturing. She is a…
tl;dr: I recently returned from my first visit to Brazil, where I spoke at a Lean Six Sigma conference, led a workshop on Process Behavior Charts, and visited two organizations applying Lean principles. From churrascarias to Gemba walks, this trip…
Last week was our first "Symposium on Learning Organizations" where we brought together 40 people with diverse backgrounds in manufacturing, healthcare, IT, government, and other industries or professions together to learn from each other in a "PowerPoint-free zone."
In this post, I'll share some photos and reflections on our tour of the Toyota truck plant in San Antonio (TMMTX). The visitor center has been completely revamped from my last visit, just as the one visitor center I saw in Japan back in March had been redone.
Today, I'll be touring the Toyota truck plant in San Antonio again, the plant known as TMMTX. I'm there with our "Symposium on Learning Organizations" group, all 40 of us. In this post, I share some pre-tour goals and share some links to previous Toyota plant visits (in Texas and Japan).
