Somewhere along the way in my career, someone handed me a copy of “The Toyota Production System,” published by Toyota Motor Corporation in April 1992. I don’t remember who gave it to me. The document itself is unassuming – a…
Mike Stoecklein recalls a story secondhand. It was, he thinks, at one of the last four-day seminars W. Edwards Deming ever gave. Deming was frail by then. Someone later told Mike that when the seminar got to the Red Bead…
There’s a hospital somewhere this quarter presenting a labor efficiency story to its board. A unit that used to have a dedicated charge nurse now has a “Working Charge Nurse” – someone who takes patients and runs the unit. The…
Ford spends roughly $100,000 a year on each of its first-line production supervisors. The title on the job posting is “Process Coach” – language borrowed directly from Lean thinking. The role description talks about Sounds great, right? Online job board…
In 2007, I wrote about a BBC article that included a number I’ve never quite been able to shake. Workers at Toyota’s Georgetown, Kentucky plant were pulling the andon cord – the mechanism that lets any worker stop the line…
I watched the HBO documentary “Fukushima: A Nuclear Nightmare” the other day. It’s chilling. The film gives a detailed account of the nine days after the March 2011 earthquake and tsunami, focusing on the workers who risked their lives to…
Tesla builds cars in what used to be the NUMMI factory, a joint venture between Toyota and GM (which meant it was run as a Toyota plant with "Lean" practices). Before that, it was a dysfunctional GM plant. Now that it's a Tesla plant, did they learn from Toyota or does it seem more like "the old GM?"
Jamie Bonini described a person who looks like 25% overhead to a finance team — but without whom the entire Toyota Production System falls apart. Bonini is the vice president of Toyota’s Production System Support Center (TSSC), which has spent…
Dr. Eric Dickson spent the early part of his leadership career telling people what to do. It nearly cost him everything. What he built after that failure — over 23 years and eventually across a $5 billion health system —…
If you’ve used ChatGPT, you’ve seen the small text at the bottom of the screen: “ChatGPT can make mistakes. Check important info.” I noticed it again the other day and thought (and wrote on LinkedIn) — I need the same…
TL;DR: A sound check, live song requests, and a naming regret — what watching Brandi Carlile perform taught me about specific problem-solving, vulnerability, and continuous improvement. My wife and I got to see the amazing Brandi Carlile perform near Chicago…
TL;DR: NUMMI proved in the 1980s what healthcare is still learning today: you can’t punish your way to safety. Real improvement comes from mutual trust, system thinking, and leaders who respond to problems with curiosity–not blame. When we talk about…
