Tag Manufacturing

Manufacturing Leadership, Lean Systems, and Continuous Improvement

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.

All (6492)3 Strategies (5)30 Rock (5)3P (10)5 Whys (18)5 Whys Survey (10)5S (134)A Lean Guy Reads (13)A.I. (1)A3 (47)A3 management process (1)A3 Open Mic (1)A3 thinking (2)Access (1)Accountability (4)Accounting (13)Ackoff (2)Adam_Zak (8)Admin (1)Adult Education (1)Adult Learning (1)Aerospace (1)Africa (2)Agile (15)AI (34)AI Lean Coach (14)Alaska (3)Alcoa (6)Alfie Kohn (2)Alternate History (1)Amazon (30)AME (6)American Airlines (7)Andon (40)Ankit_Patel (3)Apple (30)April Fool (12)Artificial Intelligence (3)ASQ (8)Auction (2)Audio (197)Audiobook (2)Australia (3)Authentic Conversations (1)Auto Industry (1)Autoliv (1)Automation (5)Automotive (14)Aviation (119)Backlog (10)Bad Systems in the News (8)Bahri (4)Baker (1)Baldrige (7)Balle (10)Banking (3)Bar (2)Bar Rescue (2)Baran (7)Barnas (3)Barnes Jewish (5)Baseball (28)Basketball (3)Batching (2)Batz Foundation (5)Beer Game (1)Being_The_Change (1)Belts (1)Benchmarking (4)Berwick (25)BIDMC (3)Billion Dollar Company (1)biofuels (1)Birth of Lean (1)Blame (159)Bliss (8)Blog Admin (88)Blog_Admin (2)blur (1)BMW (3)Board (1)Bob Emiliani (4)Bodek (78)Boeing (50)Bonini (9)Books (280)Boston (7)Brain (1)Brazil (5)Brophy (1)Buck (2)Burnout (7)business (1)Business Leadership (1)Bussell (1)Byrne (2)C-Suite Leadership (1)Cable (1)Calendar (1)Call Centers (2)Canada (101)Cancer (1)Capacity (1)Cardinal Health (13)Careers (36)Carnival (16)Carrie Schurman (9)Cartoon (7)Castle (5)Catalysis (22)Catchball (2)Cath Lab (1)Cats (1)CEO (183)Certification (1)CFO (1)Challenge (1)Change (57)Change Management (72)Changeover (2)ChangeThis (3)Charity (1)Charts (3)Charts and Graphs (3)ChatGPT (10)Checklist (14)Checklists (61)chemicals (1)Chick-fil-A (3)China (75)China Trip 2016 (6)Chrysler (33)Cincinnati (1)Cleveland Clinic (21)Clinic (1)CMS (1)CNN (1)Coaches (1)Coaching (100)Coffee (7)Collaboration (1)Comedy (5)Command and Control (12)Comments of the Week (1)Communication (2)Communications (8)Community (1)compassion (1)Compliance (1)Condo (4)Conference (1)Conner (1)Construction (6)Consulting (6)Contest (23)Continuous Deployment (1)Continuous Improvement (58)Convis (17)Cooking (3)Corrections (4)Cost (34)cost reduction (1)Costco (1)Countermeasures (1)Covey (7)Covid-19 (54)Covid-19 Pandemic (2)Creative Safety Supply (1)Creative Thinkers (1)Creativity (2)Crisis (1)Critical Strategic Decisions (1)Cross Training (2)Culbert (1)Culture (432)Culture Clash (1)Culture Of Improvement (1)Cunningham (6)Customer (1)Customer Experience (4)Customer Focus (59)Customer Satisfaction (7)Customer Service (12)Cycle Time (1)Dager (2)Daily Management System (5)Dallas (4)Dan Pink (12)Dan_Jones (8)Dan_Pink (13)Danaher (14)Data (1)DC Lean Tour (5)Defect (4)Defects (11)DEI (4)Dell (43)Delphi (13)Demand (1)Deming (488)Dentist (1)Denver (6)Denver Health (3)Design (11)Design Thinking (5)Detroit (3)Detroit 3 (1)Detroit Three (27)developing solutions (1)DFW (1)Digital (1)DirecTV (3)DMAIC (3)Doctor (180)Don Wheeler (49)Doofus (5)dr (1)Dr. Muda (6)Drucker (2)Dynamic Environment (1)Earthquake (1)Ebola (5)Economics (1)Edmondson (21)Education (34)Efficiency (4)Electric Car (1)Elon Musk (4)Email (2)Emergency (29)Emergency Dept (61)Emil (1)Emiliani (23)Emoji (1)empathy (1)Employee Engagement (17)Employee Voice (1)Empowerment (2)EMR (9)Enabling Bureaucracy (1)Energy (3)Engagement (2)Engand (1)England (45)Entrepreneurship (5)Ephlin (12)Equity (1)Ergonomics (3)Eric Ries (41)Errors (7)Events (6)Everyday Lean (109)Evidence-Based Medicine (1)Excuses (1)Exercise (3)ExperienceChange (7)Experiment (3)Experimentation (3)Eytan (1)Facebook (2)Factory Physics (2)Facts (1)Fail (3)Failure (18)Family (1)Family Guy (1)FastCap (8)Fear (28)Fearless Organization (1)Finland (1)Fire Fighting (5)Fitness (1)Flashback (5)Flexing (2)Flinchbaugh (186)Flow (28)FMEA (4)Fol (1)Food (6)Football (10)Forces Of Destruction (1)Ford (98)Fort Worth (1)FORTUNE (3)Fox News (2)Franciscan (46)Franciscan Videos (8)Fujio Cho (3)Fun (2)Funny (75)Futility (3)Galsworth (10)Gaming the Numbers (43)Garrison Brothers (3)Gas Station (1)Gawande (32)Geisinger (1)Gem (1)Gemba (167)Gemba Academy (9)Genchi Genbutsu (4)General Electric (71)General Motors (10)Germany (3)Gert (2)Gets it Wrong (4)Gilbreth (6)Glover (3)GM (177)Go To Market (1)Goals (1)good jobs (1)Good Jobs Strategy (1)Google (10)Government (139)Green (37)Grey's Anatomy (3)Grocery (2)Group Health (8)Growth Mindset (1)Grunden (16)Gruner (9)Guest (106)Guest Post (29)Guthridge (7)Habit (4)Hajek (1)Hamel (1)Hamilton (3)Hand Hygiene (7)Hanover (7)Hansei (8)Harada (4)Hawaii (1)HBR (2)Health (3)Healthcare (2003)Healthcare Kaien (1)Healthcare Kaizen (99)Healthcare Reform (1)Healthcare Value Network (1)Hebert (1)Heijunka (17)Henry Ford (5)Heparin (3)Hershfield (1)HIMSS (2)hiring (1)Hoeft (1)Honda (6)Honesty (1)Honeywell (2)Honsha Trip (5)Hopkins (1)Hoshin (15)Hoshin Kanri (4)Hospitalist (2)Hotel (5)HP (1)Huddle (13)Huddles (1)Human Error (7)Human Resources (1)Humane (1)Humility (23)Hunmtz (1)Huntzinger (4)IBM (2)ICU (1)If Japan Can (3)IHI (6)IIE Blog (1)IKEA (1)Imai (34)Improvement (5)Incentives (7)India (3)Industrial Engineering (1)Industry Week (7)Infections (12)Innovation (46)Inspection (7)Intel (1)Interview Process (1)Interviews (5)Inventory (45)investing in employees (1)Iowa (17)iPad (1)Ireland (2)Irony (1)Israel (1)IT (7)Italy (1)Jaben (4)Jackson (1)Jacobson (5)James (2)Japan (118)Japan Tour (62)Japanese (1)Jidoka (7)Jimmerson (1)Jobs Bank (11)Joiner (2)Joint Commission (3)Jon Miller (5)Jones (2)JPS (4)Just Culture (11)Just in Time (2)Just-In-Time (68)Kach (11)Kaikaku (1)KaiNexus (242)Kaizen (719)Kaizen Event (19)Kaizen Kickoff (1)Kaizen Live (12)Kanban (53)Kaplan (6)Karen Martin (9)Karyn Ross (7)Kata (28)Katie Anderson (26)kind leadership (2)Kindle (2)Kindness (6)Kitchen Nightmares (4)Knowledge Management (1)Kodak (1)Krafcik (2)L.A.M.E. (6)Lab (10)Laboratory (55)Laedership (1)LAME (109)Larry Culp (27)LaSorda (6)Law (4)Layoffs (92)Layout (12)Leader Standard Work (4)Leadershihp (1)Leadership (909)leadership lessons (1)leading with humility (1)Leadreship (1)Leadrship (2)Lean (20)Lean Accounting (1)Lean and Mean (9)Lean Coffee Talk (9)lean community (1)Lean Daily Management (14)Lean Dentist (34)Lean Design (37)Lean Edge (1)Lean Enterprise Institute (1)Lean Hospitals (82)lean leadership (2)Lean Management (14)Lean Management System (4)Lean Memes (6)Lean Mindset (8)Lean Nation (1)Lean Office (3)Lean Pathways (2)Lean Principles (1)lean production (1)Lean Sigma (19)Lean Six Sigma (11)Lean Solutions (15)Lean Startup (90)lean startup principles (1)Lean Startup Week (10)Lean thinking (2)Lean Thoughts (2)Lean toolbox (1)Lean transformation (2)Lean UX (1)Lean Whiskey (60)LeanBuzz Poll (1)LeanPub (10)LeanStartupWeek (1)Leantoon (1)Leape (7)Learning (2)LEI (103)Length of Stay (1)Lessons Learned (1)Levy (1)Library (1)Lifehacker (1)Like Lean (29)Liker (52)Linked (1)LinkedIn (29)Lippold (1)Listening (1)Livonia (9)Locher (1)Logistics (1)Lopez (18)Lucid (1)Management (9)Management by Emoji (1)Management System (1)Manufacturing (213)Manufacturing Business (1)Marketing (2)Markovitz (41)Mary Greeley (6)Materials (2)Matt_May (18)Maurer (3)MBA (1)McDuffee (13)McMahon (1)Measures of Success (75)Medical Mistakes (4)Medicare (1)Medium (11)Meier (26)Meijer (1)Memoriam (8)Menlo Innovations (1)Mental Healthcare (1)Mentoring (1)MEP (7)Merck (2)Metrics (54)Mexico (7)Meyer (2)Michigan (16)Micklewright (10)Microsoft (1)Military (46)Mindset (1)Mistake (4)Mistake-Proofing (184)Mistakes (144)MIT (13)MIxtape (179)Model Cell (1)Model Line (1)Moneyball (1)Montreal (1)Moral Injury (1)Morale (3)Motion (4)Motivation (1)Motivational Interviewing (28)Motorola (1)Move (25)Movies (1)Moving (2)MRI (1)MRP (1)Muda (3)Multitasking (1)Mura (1)Muri (3)Music (6)MVP (1)My Favorite Mistake (35)NASA (1)negative bias (1)Nervous System (1)Netflix (1)Netherlands (13)New Zealand (12)NGO (1)NHS (6)NICU (2)Nissan (8)Noble (2)Non-Profit (2)Nonprofit (1)Norval (2)NPR (13)NUMMI (75)NUMMI Tour (6)Nursing (97)NYT (2)NYTimes (85)O.R. (1)Office (8)Ohba (1)Ohio (1)Oil (1)OKRs (2)ONeill (57)Ontario (2)Operating Room (32)operations management (1)Operations Science (1)Organization Building (1)Organizational Behavior (2)organizational development (1)Oscars (6)Outpatient (1)Overburden (3)Overprocessing (14)Overproduction (20)Packaging (2)Par (1)Park Nicollet (14)Parodies (2)Parody (14)Parry (1)Pascal Dennis (16)Patient (5)patient care (1)Patient Experience (4)Patient Flow (78)Patient Focus (4)Patient Safety (383)Patient Satisfaction (10)Patients First Culture (1)Patrick_Anderson (5)Paul Akers (6)PBC Case Studies (38)PBC-Compare (4)PDCA (24)PDSA (72)People Development (1)Perfection (1)performance driver (1)Performance Measures (5)Performance Review (1)Performance Reviews (6)Pharmacy (41)Phlebotomy (1)Phoenix (1)Physician (17)Physicians (1)pink (1)Pittsburgh (2)Pivot (1)Pizza (4)Pod (1)Podcast (536)Podcast - Bodek (15)Podcast - CEO (45)Podcast - Deming (17)Podcast - Docs (45)Podcast - Healthcare (149)Podcast - Kaizen (12)Podcast - Lean Startup (14)Podcast - LEI (15)Podcast - Toyota (23)Podcast - Womack (6)Podcast 20 Years (4)Poka Yoke (5)Politics (2)Poll (2)Porsche (3)Power Of Kata (1)Practice (2)Practicing (1)Practicing Lean (25)Preventative (1)Primary (1)Primary Care (3)Prius (5)Private Equity (1)Problem (1)Problem Solving (173)Problem-Solving Approach (1)Problems (4)Process (4)Process Behavior Charts (115)Process Design (2)Process Improvement (5)Product Development (7)Product Market Fit (1)Productivity (10)Profit = Price - Cost (40)profitability (1)Pronovost (10)Psychological Safety (112)Psychology (2)Publishing (10)Pull (5)Punishment (3)Quaid (11)Quailty (1)Quality (335)Quality Circle (5)Quality Digest (20)Quebec (1)Quick Hits (1)Quotes (1)Radio (8)Radiology (10)Rapid Improvement Event (4)Reader Questions (55)Reading (23)Recruiting (3)Red Bead (16)Red-Green (6)Reflection (2)Remote Work (1)Research (1)Resilience (1)Resistance (7)resp (1)Respect (6)Respect for Business (1)Respect for People (280)Restaurant (55)Results (1)Retail (34)Retaurant (1)Review (3)Rewards (1)Rhode Island (1)Richardson (1)Rivian (1)ROI (3)Root Cause (4)Root Cause Analysis (2)RootCauseRacism (16)Rother (12)Russia (4)Safe Environment (1)Safety (173)Sales (4)San Antonio (1)Saskatchewan (9)Sayer (2)Scholtes (3)Scientific Thinking (1)Scotland (2)Scott & White (2)Searching (4)Seasonality (1)Seattle (26)Seddon (4)Senge (1)Sensei (3)Servant Leadership (2)Service (4)Services (3)Seth Godin (2)Shannon (6)Shewhart (2)Shingo (58)Shingujitsu (5)Shipping (1)Shook (62)SHS (18)Signs (14)Simmer (1)Simpsons (3)Sin (1)Siren Song (14)Six Sigma (103)Small Tests of Change (1)SMED (10)Software (78)Southwest (3)Soviet (2)Space (4)SpaceX (1)Spaghetti Diagrams (1)Spain (1)Spanish (1)SPC (29)Speaking (10)Spear (37)Spearman (1)Sports (181)SQDC (4)Standardization (2)Standardized Work (221)Starbucks (57)Startup (2)Startups (30)Statistics (2)Strategy (19)Strategy Deployment (32)Strong America (2)Struggles (4)Studer (21)Stuff (1)Stupid (2)Suggestion (2)Suggestion Box (28)Suggestions (6)Supervision (1)Supply Chain (55)Surgeon (3)Surgery (6)Sushi (1)sustainability (1)Sustainable Workplace (1)Sutton (1)Swartz (13)Sweden (8)System Dynamics (2)Tacky Advertising (1)Taiichi Ohno (70)Takt (5)Targets (1)Taylor (5)Taylorism (33)Teaching (1)Team (1)Team Building (1)Teamwork (4)Tech Support (3)Technology (10)TechSolve (2)Telecom (1)Tesla (15)Tetreault (1)Texas (5)The Jerk (1)The Mistakes That Make Us (58)The Office (4)The Resident (1)ThedaCare (206)ThedaCare Center (9)Thelen (5)Throwback (59)Tiered Daily Huddles (1)Time (3)TMMTX (3)Toast (6)Tom Peters (12)Toronto (1)Toussaint (128)Toyota (645)Toyota 1992 Booklet (5)Toyota culture (4)Toyota Kata (19)Toyota leadership (1)Toyota management (3)Toyota mentality (2)Toyota Production System (6)Toyota system (1)Toyota Way (2)Toyotas (1)TQM (10)Training (9)Training Within Industry (66)Transformation (3)Transparency (2)Transportation (2)Trash (1)Travel (62)True North (1)Trump (3)Trust (5)TSSC (8)Turgeon (13)Twitter (19)UAW (1)Uber (3)Understanding Variation (4)Unicorn (1)Union (3)Unions (3)United Technologies (1)UPS (8)USA Today (15)User Experience (1)User Interface (1)VA (15)Vaccination (12)Value (29)Value Capture (31)Value Steam (1)Value Stream (9)Value Stream Mapping (39)ValuMetrix (2)Van Dongen (5)Variation (10)Veterinary (7)VetMed (7)VIBCO (21)Video (262)Virginia Mason (114)Virtual (2)Vision (1)Visual Displays (3)Visual Management (52)Voice of the Customer (3)Volkswagen (1)Wachter (5)Wagner (21)Waiting (7)Walgreens (3)Walmart (12)Walters (5)Warning (5)Washington (2)Waste (149)waste elimination (1)Water (2)Webinar (96)Website (1)Weekend (3)Weekend Fun (21)Weight (1)Welch (6)Wellman (4)Wells Fargo (1)Wetzel (1)Wheeler (1)Whiskey (28)Whisky (3)Whole Foods (3)Wine (12)Wiremold (5)Wisconsin (23)Womack (107)women leaders (1)work culture (2)Work Design (1)Workaround (8)Workarounds (1)WorkOut (1)Workplace Culture (2)Workshop (6)Workshops (1)Wrye (3)WSJ (203)Yahoo (1)Yokoten (1)Zappos (1)Zarbo (1)Zero Defects (1)Zero Harm (6)Zoom (2)

A Lean, Sign-Making Machine

Century Sign Builders is a Lean, green machine – MSNBC.com Here is a nice case study news story about a small sign making company that has used Lean, working with the New Mexico MEP program, to help grow their business.…

Lean Suits Story on NPR

NPR : Suit Maker Goes ‘Lean’ to Keep Jobs in U.S. I’ll comment more on this later, but this was on NPR this morning. Overall, positive mentions of lean, although there was a common complaint from a worker about having…

A Wisconsin Lean Story

Metal expands when it’s hot Here’s a story from a small company that’s grown from $3m to $10m in revenue, in part due to Lean methods, but also due to apparent notions of “respect” for employees and customers. There are…

How Specific an Example Do You Need?

From the Northwest Lean Network email listserv, about a week ago: ” I am looking for experiences using lean practices and tools in fruit juice businesses.” I’ve seen a lot of this, people asking for very specific examples of lean…

WSJ is STILL Shocked We Build Stuff Here

For Some Manufacturers, There Are Benefits to Keeping Production at Home – WSJ.com This really is a recurring theme in the WSJ, this article starts: “It has long been an axiom that U.S.-made consumer goods such as TV sets and…

New Dave Gleditsch IW Column

IndustryWeek : Transforming Your Business To Lean: Lessons Learned Here’s the latest column by Pelion Systems CTO Dave Gleditsch, featured here in an earlier LeanBlog Podcast, with some case studies of lean success at American Standard and Husqvarna. Dave’s main…

Calling DFW or Texas Lean Companies

Personal request — I’m looking for a Dallas/Fort Worth area company that is in an advanced state of lean implementation. (that’s quite a flexible definition of what “advanced” means, obviously). West Texas (Lubbock, Midland/Odessa, Abilene, El Paso) or Central Texas…

Hiding Defects in the Ceiling

USA’s only breast implant factory adjusts to silicone approval (USA Today) First off, shame on the journalist for using the “everything is bigger in Texas” cliche in her story. About my headline… yes, that’s not referenced in the USA Today,…

Boeing Still Improving with Lean

Manufacturing overhaul will help Boeing avoid bottlenecks – MarketWatch Here’s a Wall St. analyst who is actually high on their lean efforts: “The key behind lean manufacturing is not just the margin improvement, but the fact that you can produce…

Searching the Shopfloor Investment Value

Wilbur Ross moves into the auto-parts industry – December 11, 2006 I referenced this article from FORTUNE a few days ago, but here’s an individual post. Wilbur Ross and his team walk shop floors looking for opportunities. Does anyone know…

TV’s Made in the USA

Olevia opens U.S. LCD and LCos Assembly Plant at Digital Pipeline I was reading an article in the NY Times today about a downturn in manufacturing orders. What shocked me was the photo that accompanied the article. The caption showed…

An AI that won't just give you the answer. That's what makes it useful.Free Demo -- Learn More
+ +
lean coach ad