Manufacturing is where many Lean ideas were first developed—but lasting results never come from tools alone. This archive explores manufacturing through the lens of leadership, safety, culture, and systems thinking, drawing lessons from real plants, executives, and frontline experiences that still matter today.
From Toyota and NUMMI to modern aerospace, appliance, and industrial operations, these posts show how manufacturing excellence depends on respect for people, learning from problems, and designing systems that make the right work easier.
The results came fast. A year in, the defect rate was down, the turnaround time was down, teams had A3s on the wall and could talk about them. Then it flattened. Not a collapse. Just nothing more. Somebody says the…
When the door from the office area opened onto the production floor at Toyota’s plant in Durban, South Africa, I heard a familiar sound from other Toyota plants I’ve visited: the andon music. Earlier this month, before speaking at the…
Three years ago, I wrote about GE CEO Larry Culp’s habit of beginning every investor meeting with a safety briefing and his insistence that the company’s priorities should be safety, quality, and delivery–before cost. See “GE’s CEO Larry Culp on…
For years, I’ve been asking a very specific question about Lean history: Where was Toyota’s first andon cord? Jeff Liker didn’t know. Neither did Isao Yoshino. I’ve asked other former Toyota people. Toyota histories and books about the development of…
The kaizen board held a couple dozen sheets. Each one numbered, each one stamped “jisshi-zumi” — already done. A board full of carried-out improvements is a strong sign in any factory, in any country. But that wasn’t the part that…
On a factory table in Japan, in December 2019, there was a binder. White cover, the word KAIZEN in big orange letters, a photo of cherry blossoms underneath. Inside the front cover, someone had printed a word cloud — IMPROVEMENT,…
Gary Peterson spent almost 40 years helping O.C. Tanner build a continuous improvement culture, work that earned the company the Shingo Prize in 1999. He joins me to talk about psychological safety, autonomy, leading change from the middle, and the…
Why do so many quality programs fall apart the moment the firefighter walks out the door? In this conversation, Chad Diggs talks about his new book, Below the Surface, and what it takes to build quality systems that outlast the people who…
A food company had a flowchart any auditor would love. Every step mapped. Every step mapped. Every critical control point identified. The HACCP plan (Hazard Analysis and Critical Control Points, the standard food safety framework that identifies where contamination can…
Scott Burgmeyer, founder and CEO of Become More Group, has spent more than 30 years watching smart people make avoidable decisions — not because they lack intelligence, but because they stopped thinking. In this episode of Lean Blog Interviews, we…
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…
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?"
