Lean 911

What if the biggest transformation in your life begins with a simple shift in perspective—not from believing life is happening to you, but realizing it is happening through you? In this episode, we explore Be The Magic...

As Lean Horizons celebrates its 25th anniversary, founder Mark DeLuzio reflects on a quarter century of transformation work across six continents and dozens of industries. In this special episode, Mark examines the...

A CNC machine crashed on the shop floor. Nathan Corliss walked out as a young supervisor, angry and ready to blame the operator. What happened next became one of the most important leadership lessons of his career. Mark...

<p>This is an unedited replay of a previous Lean 911 episode, originally published on January 13, 2023. We're bringing it back because the issue still causes Lean transformations to stall, drift, or flatline.</p> <p>One...

<p>In this episode, we dive into the rise, dominance, and controversy surrounding Six Sigma — the corporate improvement system that promised near-perfect quality and became a management obsession across America. From...

<p>Manufacturing Engineers pride themselves on precision, but what if the biggest waste is hiding in plain sight—inside the equipment itself?</p> <p>In this episode, we challenge the status quo: excess feeds, slow...

<p>In this powerful episode of Lean 911, Mark DeLuzio sits down with former Air Force fighter pilot and Danaher sales leader Randy Fitzhugh to unpack the real science behind value selling and why most organizations get...

<p>Lean management teaches that standards are the foundation of safety, quality, and improvement. In aviation, those standards take the form of checklists, redundancies, procedures, and strict cockpit protocols designed...

<p>Mark DeLuzio, the Father of Lean Accounting, tells his experience and observations on how traditional cost accounting will derail a Lean Transformation.</p> <p>In many organizations, Lean transformations don't fail...

<p>In this episode, you'll be able to take away why many "logical" workplace measures and incentives can drive behavior that conflicts with Lean principles, and why comparing work decisions to everyday home-life...

<p>A shop floor comment stops everyone in their tracks: the work finally matches what the customer actually needs. That is the spark behind Accidentally Aligned, and it opens a bigger issue most leaders dodge: alignment...

<p>Most Lean efforts do not stall because people hate improvement. They stall because the system was never built to support it.</p> <p>This episode gives you a fast, practical lens for evaluating whether your...

<p>Mark DeLuzio discusses how the 2-Bin Kanban is meant to ensure the operator does not run out of parts. Find out why it should not be used to structure your primary Kanban system.</p>

<p>Mark DeLuzio discusses the confusion that exists in the Lean Community, and the Lean Consulting industry and academia are primarily to blame. Returning to Lean Basics and ignoring distractions like Kata, Gemba Walks...

<p>Mark DeLuzio discusses the absence of engineers from the Gemba in both manufacturing and design. He also discusses the sin of engineering, which he calls "Catalogue Engineers." </p>