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.
In a webinar I hosted with Sandro Casagrande from Electrolux, we reflected on the 20-year evolution of their Electrolux Manufacturing System (EMS). One of the highlights was hearing how KaiNexus became part of that journey starting in 2017. You can…
KaiNexus recently hosted a webinar I was especially looking forward to: “Unlock the Power of Leadership: The Electrolux Manufacturing System (EMS) Way,” presented by Sandro Casagrande from Electrolux. The session took place on December 10 at 1 pm Eastern, and…
Why do so many Lean efforts stall after early wins? In this episode, Darren Walsh explains why firefighting feels productive but prevents real progress–and how leaders can build daily routines and standards that sustain improvement over time. Scroll down for…
TL;DR Larry Culp, CEO of GE Aerospace, shows that Lean leadership isn’t about tools or slogans–it’s about daily behaviors. By grounding Lean in safety, respect for people, and continuous improvement, Culp practices kaizen at every level, including his own role…
TL;DR: Lockout/tagout failures kill workers every year–and they’re not “operator errors.” This post explains why ignoring LOTO is a leadership and culture failure, why productivity pressure drives deadly shortcuts, and what Lean leaders must do to put safety truly first.…
Scroll down for how to subscribe, transcript, and more My guest for Episode #535 of the Lean Blog Interviews Podcast is Gregg Stocker, a seasoned Lean practitioner, consultant, and author. Over the past 30+ years, Gregg has worked across industries,…
This summer marked 30 years since I started my first job out of college–working as an engineer at a General Motors engine plant in Livonia, Michigan. It’s strange to say that out loud. In some ways, it feels like yesterday.…
In this episode of the Lean Blog Interviews Podcast, Dale Lucht reflects on the leadership habits that separate short-lived Lean gains from lasting cultural transformation–and the mistakes leaders must stop repeating. Scroll down for how to subscribe, transcript, and more…
This edition of Ryan McCormack’s Operational Excellence Mixtape examines the shifting balance between people, systems, and strategy in the pursuit of better performance. From Toyota’s hospital and vineyard-to-glass winemaking to the limits of automation at Starbucks, the selections highlight how…
At its core, Lean is about people–respecting them, empowering them, and ensuring their well-being while driving continuous improvement. Recently, GE Aerospace’s Lynn, MA, facility provided an inspiring example of what it means to put these principles into action, even under…
As a Lean practitioner, I found the Wall Street Journal article about Ryan DeLand, the 39-year-old leader of Whirlpool’s washing machine plant in Clyde, Ohio, to be fascinating. Here’s a free link: A Day in the Life of the 39-Year-Old…
Scroll down for how to subscribe, transcript, and more My guest for Episode #520 of the Lean Blog Interviews Podcast is Bill Remy, CEO of TBM Consulting. Bill is both an accomplished business executive and leader who is frequently called…
