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.
I recently read this article on the IndustryWeek website:
Whirlpool's Green Takes Aim at World Class Manufacturing
Byron Green, the vice president of manufacturing for Whirlpool's 14 factories in the U.S. and Mexico, said:
"...manufacturing was littered with companies that saw lean as a collection of tools that could be deployed for a quick win. Successful companies, he said, instead see it as a bedrock of their culture."....
Any rare event creates a number of challenges when it comes to manufacturing and supply chains. We're seeing a pretty historic "spike" in demand for products like the inexpensive glasses that allow one to safety view the eclipse (our friends in the totality zone can look at the totally-eclipsed sun safely, but that's the only time).
You could call it "supply chain challenges" or a "lack of planning on my part," but I cannot find eclipse glasses anywhere. There are MANY articles online about this widespread problem -- it's been impossible to buy "eclipse glasses" anywhere. Why is this? What could have been done?
Mark’s note: I somehow stumbled across this 2002 HBR article, Read a Plant–Fast, so I asked regular guest blogger Paul Critchley to write a post about it and his thoughts. Personally, I think it’s fair to refer to Lean transformations as…
In today's post, Jason Morin, from XPO Logistics, writes a review of Jim Lancaster's recent book "The Work of Management," published by the Lean Enterprise Institute. Jim Lancaster is CEO of Lantech and the book tells the story of their Lean journey and their evolution over time.
It’s almost Thanksgiving here in the United States, so I’ll be taking the rest of the week off from the blog to enjoy some downtime with family. Improving operations, usually through Lean, was my main job in different manufacturing companies…
Joining me for Episode #258 is a many times returning guest, Jim Huntzinger, the President and Founder of Lean Frontiers (check out Episodes 8, 15, 33, 196, and 251, his with Russ Scaffede). Jim has written two eBooks, The Roots of Lean: Training Within Industry: The…
I’m really excited to have Steve Bera as my guest for episode #256 of the podcast. I read about him as he was featured prominently in a chapter of the 1994 Pulitzer-Prize winning book Comeback: The Fall & Rise of…
Scroll down for how to subscribe, transcript, and more This episode is sponsored by StoreSMART. My guest for episode #255 is Mark DeLuzio, author of the recently released book Turn Waste into Wealth: How to Find Cash in Every Corner of…
I’m a car guy. Above all other mechanical devices that we engineers get to be involved with, I am fascinated most with these incredible machines. When you consider how automobile soperate nearly flawlessly even when enduring a spectrum of environmental…
tl;dr: Lean doesn’t mean “zero inventory” — and it doesn’t mean eliminating waiting rooms either. In both manufacturing and healthcare, low inventory and less waiting are outcomes of capable, reliable processes, not goals to chase through absolutes. For decades, manufacturers…
I've written before about the subject of hospitals "flexing" nurses and employees. I've criticized flexing (or the practice of sending employees home early because patient census is low) and I've pointed out that it's not keeping with "Lean" principles to "save money" by sending people home early.
As a guy who started his career in manufacturing before moving to healthcare in 2005, I don’t get many opportunities to visit the “Gemba” at a factory very often anymore. I get to occasionally visit a Toyota plant (in the…
