Lean Blog Interviews - Healthcare, Manufacturing, Business, and Leadership

Mark Reich, Former Toyota Leader on Hoshin Kanri and 'Managing on Purpose'

My guest for Episode #528 of the Lean Blog Interviews Podcast is Mark Reich, a Senior Lean Coach with the Lean Enterprise Institute and former Toyota leader with over two decades of experience.
Episode page with video, transcript, and more
Mark spent six years working in Japan, including helping launch the Lexus brand and later leading Hoshin Kanri strategy processes during Toyota's rapid growth in North America. He also played a pivotal role at the Toyota Supplier Support Center (TSSC), helping bring the Toyota Production System to manufacturing, healthcare, and nonprofit organizations. In our conversation, we dive into his career journey, his approach to Lean leadership, and the practical lessons behind his new book, Managing on Purpose: Using Hoshin Kanri to Develop Strategy, Align Teams, Grow Leaders, and Innovate Your Enterprise.
You can get a 25% discount on the book via LEI using the code LBIPODCAST25.
Mark shares compelling stories from his early days at Toyota, including working on the front lines of assembly, learning by doing, and his first experience pulling the andon cord. These moments shaped his appreciation for Toyota's deep respect for frontline work and its commitment to developing people. He reflects on how Toyota embeds learning and support into problem solving, where pulling the cord is seen as a learning opportunity, not a failure. That mindset became foundational for his later work, especially when managing enterprise-wide strategy through Hoshin Kanri.
We also explore what Hoshin Kanri really is--and what it isn't. Mark challenges the overemphasis on tools like the X-matrix and instead advocates for focusing on purpose, alignment, and leadership behavior. He explains how strategy deployment at Toyota was never a one-way cascade, but a dialogue grounded in humility, curiosity, and shared responsibility. Whether you're new to Hoshin or struggling to sustain it, Mark offers insights that can help any leader make strategy a living, breathing part of organizational culture.
Questions, Notes, and Highlights:
How did you end up working for Toyota, and what led you to Japan?
What was your educational background, and did you already speak Japanese before moving there?
What was your initial role at Toyota, and how did it relate to their global expansion?
Did you meet or work with John Shook during your time in Japan?
How did Toyota develop you into an industrial engineer despite your background in English writing?
What was it like working in a Toyota plant, and what did you learn from that experience?
Did you experience any early mistakes or learning moments while working the line?
How did your role evolve after leaving Japan, and how did you get involved with Hoshin Kanri in North America?
What challenges was Toyota North America facing that made Hoshin Kanri so essential?
How did you facilitate alignment and catchball between Toyota's plants and leadership teams?
How do you define Hoshin, strategy, and Hoshin Kanri?
Why do you prefer not to use the term "strategy deployment," and what's the issue with top-down-only thinking?
How do you coach executives to embrace catchball and bottom-up engagement?
How do you balance executive direction with frontline input in strategy development?
What role does psychological safety play in making Hoshin Kanri work?
How does A3 problem solving fit into the Hoshin process, and how does it help build capability?
Why is it important for executives to practice PDCA and engage in direct problem solving?
What's the difference between long-cycle and short-cycle PDCA, and how should leaders manage both?
Why does it take most organizations a couple of years to fully embed Hoshin Kanri?
What lessons do companies learn when they start with too many strategic initiatives?
Why did you choose not to include the X-matrix in your book, and what are your thoughts on its use?
What business problems does Hoshin Kanri best help organizations solve?
How can Hoshin Kanri help clarify the distinction between daily management and long-term strategic work
This podcast is part of the #LeanCommunicators network. 

Inside the Lean Healthcare Accelerator Experience: Japan Insights with Dave Fitzpatrick

My guest for Episode #527 of the Lean Blog Interviews Podcast is Dave Fitzpatrick, co-founder of Zenkai Improvement Partners and a 30-year resident of Japan. Dave brings a unique perspective as a Canadian Lean practitioner who has worked extensively in both manufacturing and healthcare, guiding international leaders on immersive study experiences throughout Japan.
Episode page with video, transcript, and more
In this episode, Dave and I share details about a new collaboration we're leading together--the Lean Healthcare Accelerator Experience. This is a jointly developed series of immersive visits to high-performing organizations in Japan, designed specifically for healthcare executives who want to see Lean principles in action across both hospitals and manufacturing settings. We talk about why we're creating this experience, what makes it unique, and how cultural context, leadership behaviors, and intentional long-term commitments drive sustainable improvement--not because it's "just Japan," but because of the systems and mindsets these organizations have cultivated.
Dave shares his personal Lean journey, including how he transitioned from working in aeronautics to leading study tours for visiting professionals. He reflects on the differences between Japanese and Western companies when it comes to employee engagement, psychological safety, and respect for people. We also preview the first Accelerator trip taking place in June 2025 and discuss what makes these experiences so valuable and transformational for participants.
Whether you're in healthcare or another industry, this conversation is packed with insights about creating a culture of continuous improvement--and how a visit to Japan can accelerate your learning.
Questions, Notes, and Highlights:
Can you share your origin story--how did you first get involved with Lean, Kaizen, or the Toyota Production System?
What initially stood out to you when you began visiting Japanese manufacturing and healthcare organizations?
From your experience, what cultural factors give Japanese organizations an advantage--or do they?
How do successful Japanese companies build deep employee engagement and commitment to improvement?
What lessons can visitors take home from Japan--and why is it not just about being "Japanese"?
What are some common misconceptions people have before visiting Japan on these study experiences?
How does hierarchy or seniority in Japanese companies affect psychological safety and speaking up?
What kinds of organizations will we be visiting during the Lean Healthcare Accelerator?
What role will Reiko Kano play in these visits, and how does her expertise go beyond translation?
What's the value of including manufacturing visits in a healthcare-focused learning experience?
How do Japanese companies view improvement work in relation to headcount and job security?
Why is respect for people and time such a noticeable theme in Japanese customer service and operations?
What do you hope participants in the Lean Healthcare Accelerator take away from this experience?
This podcast is part of the #LeanCommunicators network. 

Leading Lean for Profitable Growth: CEO Bill Canady on Driving Business Transformation

My guest for Episode #526 of the Lean Blog Interviews Podcast is Bill Canady, a seasoned global business executive, U.S. Navy veteran, and current CEO of Arrowhead Engineered Products.
Bill has led over 30 operating companies and thousands of employees across the industrial and consumer products landscape. Formerly CEO of OTC Industrial Technologies, he helped drive impressive growth-boosting revenues by 43% and earnings by 78%.
Bill is also the author of The 80/20 CEO and the upcoming From Panic to Profit, and he's a vocal advocate for using Lean and the 80/20 principle as complementary tools for transformation.
Join Bill for a live Q&A webinar on April 23rd via KaiNexus!
We discuss Bill’s personal Lean journey, which began with Six Sigma and evolved into a deep appreciation for the power of Lean and continuous improvement. He shares how daily management, Kaizen events, and a focus on flow became core to his leadership toolkit—not just on the shop floor but also across the “carpeted” functions like order-to-cash and sales. As CEO, Bill doesn’t just support Lean; he expects it. He talks candidly about making continuous improvement a condition of employment, not through fear, but by creating a culture where people feel safe, engaged, and energized by problem-solving.
You’ll hear Bill’s insights on applying Lean as a strategic enabler for profitable growth—not just a cost-cutting tool. He explains how the 80/20 principle helps companies focus their improvement energy on what really matters and how Lean helps teams sustain those improvements. He also shares real-world lessons on leadership, cultural alignment, and navigating resistance to change—especially among those clinging to old firefighting habits.
Whether you’re a Lean practitioner, an executive, or someone aspiring to lead, this conversation is packed with practical wisdom. Bill offers a compelling blueprint for how to lead with humility, clarity, and purpose—using Lean and the 80/20 mindset to build resilient, high-performing organizations.
Questions, Notes, and Highlights:
Can you share your origin story with continuous improvement and Lean?
What was the context in which you were first introduced to these methodologies?
How did your role evolve from operations into broader P&L responsibility?
How did your perspective on Lean shift when you became a CEO?
What role does daily management play in sustaining operational excellence?
How do you apply Lean principles outside the factory floor—especially in “carpet land”?
As a CEO, how do you strike the balance between solving problems yourself and enabling others to be problem solvers?
How do you respond when leaders or team members resist Lean thinking or default to old firefighting habits?
What does it mean to make Lean a “condition of employment,” and how do you introduce that mindset?
How do you ensure people understand Lean isn’t about layoffs, but about redeployment and growth?
How do you connect Lean initiatives with business growth, not just cost reduction?
Do you have an example of how improving quality or delivery led directly to business growth or profitability?
What inspired you to write your first book, The 80/20 CEO?
Why are the first 100 days so critical for a new leader?
How does the 80/20 principle help leaders prioritize improvement efforts?
What’s the relationship between 80/20 analysis and Lean execution in your approach?
What can we do to help more CEOs understand and embrace Lean as a strategic business system?
How can companies start building momentum with Lean—even if they’re just getting started?
What’s the focus of your new book From Panic to Profit, and how does it expand on your first?
This podcast is part of the #LeanCommunicators network. 

From Noise to Knowledge: Embracing Data-Driven Leadership - Christopher R. Chapman

My guest for Episode #525 of the Lean Blog Interviews Podcast is Christopher R. Chapman. He's an experienced agile coach and consultant with a background in software development and agile transformation.
Episode page with video, transcript, and more
Since founding Derailleur Consulting in 2010, he has guided teams and leaders in adopting agile frameworks like Scrum and Kanban while integrating applied systems thinking inspired by Deming and other thought leaders.
Christopher is also known for cultivating communities through initiatives such as #SystemsThinkingTO and for sharing his insights in his popular Substack newsletter, The Digestible Deming.
In this episode, Chris and I discussed our upcoming collaborative workshops--"From Noise to Knowledge, Executive Leadership Through Data Driven Insight"--scheduled for
May 13 in Toronto and
June 17 in Cincinnati.
We highlighted how the sessions will blend experiential learning, such as the Red Bead Experiment, with practical tools like process behavior charts to help leaders decode variation and improve decision-making. The conversation emphasized the Deming philosophy as a core framework, exploring how leadership behaviors and systemic practices directly impact team performance and overall organizational quality. We also noted the engaging social aspect of the workshops, mentioning optional outings to local MLB baseball games as an opportunity for continued dialogue.
The discussion then shifted to our personal journeys with continuous improvement, agile methodologies, and the evolution of leadership roles. Chris shared insights from his transition from software development to coaching senior management, focusing on moving beyond traditional, isolated team interventions toward a holistic, systems-oriented approach. We both underlined the need for leadership to embrace a mindset shift--recognizing that issues within teams often reflect broader organizational constraints. We also debated common pitfalls, such as misinterpreting data due to superficial analyses, and argued for using robust, statistical tools to establish meaningful insights, setting the stage for transformative change in management practices.
Questions, Notes, and Highlights:
How do Deming's principles transform executive leadership and team performance?
What key insights does the Red Bead Experiment offer for practical improvement?
In what ways do process behavior charts enhance decision-making in complex systems?
How can agile methodologies and Deming's philosophy be integrated effectively?
What systemic issues underlie team challenges, and how should leadership address them?
How can statistical process control complement traditional metrics in agile environments?
What strategies enable leaders to shift from reactive problem-solving to proactive system improvement?
How do extrinsic incentives impact collaboration and quality within teams?
What methods best embed systems thinking into agile practices?
How can workshop formats foster lasting changes in leadership mindsets?
This podcast is part of the #LeanCommunicators network. 

John Willis on Deming's Journey to Profound Knowledge in IT & DevOps

My guest for Episode #524 of the Lean Blog Interviews Podcast is John Willis, an accomplished IT management expert with over 45 years of experience. His extensive body of work includes contributions to Deming's Journey to Profound Knowledge and co-authoring The DevOps Handbook.
See video, transcript, and more
Hosts a podcast that I was recently on, "Profound."
John focuses his current research on DevOps, DevSecOps, IT risk, modern governance, and audit compliance. Over the course of his career, he has sold companies to Docker and Dell, and he played a foundational role at Opscode (now Chef).
In addition, John founded Gulf Breeze Software, an award-winning IBM business partner recognized for its successful deployment of Tivoli technology for enterprise clients. He has authored six IBM Redbooks on enterprise systems management and served as the founder and chief architect of Chain Bridge Systems. Altogether, John has written more than 11 books and launched over 10 startups, cementing his reputation as a significant innovator in the IT industry.
In this episode, the discussion navigates the intersection of lean principles, agile methodologies, and Deming's philosophies as they apply to modern IT and operations. John delves into how systems thinking, profound knowledge, and psychological safety underpin effective incident management and cybersecurity practices. The conversation explores practical challenges and the proactive strategies necessary for integrating legacy improvement methods with today's cloud innovations and infrastructure as code.
Throughout the episode, John examines the real-world application of these timeless principles, offering listeners actionable insights into continuous improvement and risk management. He highlights the importance of questioning established norms and embracing complexity to drive operational excellence, providing a compelling roadmap for navigating the evolving digital landscape.
Questions, Notes, and Highlights:
Could you share your origin story regarding Lean and continuous improvement--specifically, what you learned during your early years at Exxon?
How have you seen Deming's principle of eliminating fear put into practice in IT and entrepreneurial settings?
Is the phenomenon you described established fact or more of a hypothesis?
How can we confirm or measure the validity of that knowledge?
Why do you consider cyber terrorism one of today's most significant threats?
This podcast is part of the #LeanCommunicators network. 

Innovating Patient Safety: Mike Eisenberg Discusses Healthcare Technology and Trust

My guest for Episode #523 of the Lean Blog Interviews Podcast is Mike Eisenberg. He's been a filmmaker since 2010 with his production company, Tall Tale Productions, after completing his B.A. in Journalism at Marietta College in Ohio.
Episode page with video, transcript, and more
Mike’s father, Dr. John Eisenberg, was a leader in national patient safety efforts as the director of the Agency for Healthcare Research & Quality (AHRQ) until his passing in 2002. His legacy is prevalent throughout Mike’s presentation, as well as his approach.
His new documentary, released last September, is titled “The Pitch: Patient Safety's Next Generation.” 
He previously joined us in Episode #329, where we discussed his film "To Err is Human."
In 2006, Mike was drafted by the Cleveland Indians in the MLB Draft and played 3 seasons of professional baseball before beginning his filmmaking career. He now speaks at hospitals, universities, and conferences, where his insight provides a new perspective on a problem that persists across the globe.
In today's episode, we explore the evolution of patient safety and the transformative role of technology in healthcare. The conversation dives into how innovations—from advanced command centers to cutting-edge virtual reality and AI applications—are redefining how hospitals prevent and respond to medical errors. The discussion challenges the conventional blame-and-shame approach and instead highlights the importance of building systems that foster trust and resilience among healthcare professionals and patients alike.
We also examine the nuances of integrating technology into complex healthcare environments, discussing how effective communication, standardized protocols, and smart design can work together to minimize human error. Drawing insightful parallels with industries like aviation, the episode offers a fresh perspective on the critical need for systemic improvements and the potential for new technological solutions to drive the next generation of patient safety.
Questions, Notes, and Highlights:
How is technology transforming patient safety in healthcare?
What role do advanced command centers, virtual reality, and AI play in preventing medical errors?
How can healthcare shift away from a blame-and-shame culture?
What strategies build trust and resilience among healthcare professionals and patients?
How do effective communication, standardized protocols, and smart design minimize human error?
What lessons can be learned from the aviation industry regarding safety and error management?
What challenges arise when integrating technology into complex healthcare environments?
How can innovation drive the next generation of patient safety?
This podcast is part of the #LeanCommunicators network. 

Bridging the Communication Gap in Lean: What We Can Learn from Journalism with Jacquie Maupin

Episode page with video, transcript, and more
My guest for Episode #522 of the Lean Blog Interviews Podcast is Jacquie Maupin.
She joins the podcast to discuss her upcoming workshop at the Healthcare Systems Process Improvement Conference (HSPI) hosted by the Society for Health Systems. She and her co-presenter, Lauren Todd from HCA Healthcare, will lead a session titled "From Analysis to Action: Bridging the Gap with Effective Presentations" on February 19.
This interactive workshop is designed to help attendees sharpen their communication skills, structure data-driven narratives, and effectively engage executives and stakeholders. Whether you're attending this year or considering next year's event, this conversation offers valuable insights into the intersection of Lean, process improvement, and communication.
In this episode, we discuss how journalism and communication skills can enhance Lean and process improvement efforts. Jacquie shares how her background in journalism and military leadership shaped her approach to problem-solving, stakeholder engagement, and storytelling in the world of healthcare improvement. We explore the parallels between investigative reporting and Lean methodology—how asking the right questions, structuring information effectively, and communicating insights clearly can drive meaningful change.
We also dive into Jacquie's upcoming workshop, where she and her co-presenter, Lauren Todd, will guide attendees through strategies for tailoring presentations to different audiences, crafting compelling data-driven narratives, and influencing decision-making. Whether you're attending this year or looking for ways to elevate your communication skills in process improvement, this episode is packed with valuable lessons.
Questions, Notes, and Highlights:
Can you share your Lean origin story and career path?
How did your background in journalism and the military shape your approach to process improvement?
What sparked your interest in healthcare and led you to Georgetown University Hospital?
What were some of the most impactful projects you worked on at Georgetown?
How does process mapping help break down silos and improve collaboration?
What journalism skills translate well to process improvement and Lean work?
How do you approach communicating with executives to ensure your message is understood?
What challenges have you faced in presenting Lean concepts to different audiences?
How can process improvement teams better tell their success stories and demonstrate value?
What insights will attendees gain from your upcoming workshop at the Healthcare Systems Process Improvement Conference?
 

Gemba Claus is Comin’ to Town! [Song]

Here's a musical holiday treat for my regular Lean Blog readers and podcast listeners, a song parody, originally released in 2009... remastered a bit in 2022.
https://www.leanblog.org/2022/12/gemba-claus-comin-town-song/ 
Gemba Claus is Comin' to Town
Lyrics by Mark GrabanPerformance by Steve Sholtes
Oh, you'd better watch outYou'd better kaizenYou'd better not pout, I'm tellin' ya thenGemba Claus is comin' to town
He's making a listJust checking it onceDoin' it twice would waste a whole bunchGemba Clause is comin' to town
He sees you when you're waitin'He knows when your work flowsHe knows if changeovers are too longSo do SMED  for goodness sake
Oh, you'd watch outYou'd better not pauseYou'd better not poutFind the real root causeGemba Claus is comin' to Town!
For voiceover work, music, or more, you can contact Steve via his website, www.stevesholtes.com.
Merry Christmas and Happy Holidays!

Bonus: Preview of Mark Graban's AME Australia "Road Show" in 2025; Improving the Way We Improve

Welcome to this bonus session of the Lean Blog Interviews Podcast, originally recorded as a LinkedIn Live event! In this conversation, I partnered with Rebecca Michalik from AME Australia to discuss my upcoming workshops in Australia and New Zealand in March 2025.
Episode page with video, transcript, and more
We’ll dive into key themes like psychological safety as a foundation for continuous improvement and how to make smarter use of performance metrics through process behavior charts. Even if you’re outside Australia or New Zealand, the principles and practical examples we discuss have universal applications for leaders and organizations worldwide.
If you're interested in learning more about the workshops, click here.
Key Questions:
What is the purpose of the AME Australia roadshow, and what will attendees gain from it?
Why is psychological safety critical for Lean and continuous improvement?
How can leaders create an environment where employees feel safe to speak up?
What are process behavior charts, and why are they a better way to understand performance metrics?
Can you share examples of organizations that have successfully applied these principles?
What are some actionable steps attendees can implement immediately after the workshops?
Why is in-person learning particularly valuable for these topics?
How do you see these topics applying universally, regardless of industry or location?
What lessons have you learned in your career that you think every leader should know?
What would you say to someone who’s on the fence about attending?
The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network. 

Daily Management, Strategy Execution, and Lean Leadership with José Ferro

My guest for Episode #521 of the Lean Blog Interviews Podcast is  José R. Ferro, PhD, a Senior Advisor with the Lean Enterprise Institute and the Founder and President, Lean Institute Brasil.
Episode page with video, transcript, and more
By founding Lean Institute Brasil in 1999 to disseminate the principles and practices of lean thinking to Brazilian companies, Ferro helped catalyze a global movement to establish lean institutes in other countries, which ultimately grew into the Lean Global Network, chartered in 2007.
In the late eighties, he was a visiting scholar in MIT’s International Motor Vehicle Research Program (IMVP), which introduced the term “lean” to describe Toyota’s revolutionary management system.
Ferro received PhD and master’s degrees in business administration, Getulio Vargas Foundation, and production engineering from the University of São Paulo in São Carlos.
His new book, Daily Management to Execute Strategy: Solving problems and developing people every day, is available now.
In today's episode, José will share practical insights on how to integrate daily management with strategy, the critical role of psychological safety in fostering problem-solving and improvement, and lessons learned from decades of leadership and Lean practice.
So, stay tuned for an engaging conversation about Lean, leadership, and creating cultures that thrive on continuous learning and improvement!
Questions, Notes, and Highlights:
José's Lean Origin Story: How did you first encounter Toyota-related practices, even before the term “Lean” was coined?
Initial Impressions: What was your perspective on Lean’s balance between efficiency and a humane approach in its early days?
Brazil’s Lean Journey: How did the opening of markets in the 1990s influence Lean adoption in Brazil across industries?
Daily Management Framework: How do you define daily management, and what are its key elements?
Challenges of Implementation: Why is there often a gap between technical Lean tools and the social aspects like leadership and problem-solving?
The Book’s Framework: Can you explain the three foundational blocks of daily management from your book?
Leadership's Role: What’s the leader’s role in connecting strategy to daily execution?
Psychological Safety: Why is psychological safety so foundational, and how does it coexist with challenging environments?
Problem-Solving Integration: How can organizations better connect daily huddles with deeper problem-solving efforts?
Examples in Practice: Can you share real-world examples of organizations successfully applying your daily management framework?
Future Vision: Where do you see opportunities for Lean to grow in Brazil or globally, especially in non-traditional sectors?
The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.
This podcast is part of the #LeanCommunicators network.