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

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. 

Transforming Operations with Lean Leadership: Bill Remy, CEO of TBM Consulting, on Driving Growth Through Continuous Improvement

My guest for Episode #520 of the Lean Blog Interviews Podcast is Bill Remy, CEO of TBM Consulting. 
Episode page with video, transcript, and more
Bill is both an accomplished business executive and leader who is frequently called upon for his credible voice, honesty, and pragmatism — and for his ability to leverage operational excellence and continuous improvement for long-term profitable growth. 
As former president of Thayer Aerospace, Bill doubled revenue in six years, expanded into Mexico, improved profitability, and increased inventory turns. He integrated the supply chain into a web-based pull system, consolidated divisions, and implemented an ERP system. 
Earlier in his career, Bill held progressively responsible roles in operations, including Vice President of Continuous Improvement at Invensys, Vice President of Operations at Learjet/Bombardier, Production Manager at Lockheed Arizona Missile Facility, and Materials Manager at Allied-Signal Aerospace.
Bill holds both a Master of Science and Bachelor of Science degrees in Industrial Engineering from Oklahoma State University. He serves as Chairman of the Board of Directors for Pancon Corporation and on the Oklahoma State University /deans Advisory Board for the College of Engineering. He has over 25 years of leadership experience in general management and manufacturing operations.
In this episode, we discuss the transformative power of Lean leadership and operational excellence. Bill shares insights from his extensive career, including how he first encountered Lean principles at Allied Signal and the dramatic improvements achieved through lead time reduction and flow.
We explore the critical role of communication and employee involvement in overcoming resistance to change, the deep connection between safety and quality, and the importance of leadership in both driving transformation and sustaining long-term improvement.
Bill outlines TBM’s four-phase framework for turning around operations, emphasizing the need for a holistic evaluation of people, processes, and performance metrics. Finally, we reflect on how organizations can leverage Lean as a strategic advantage to drive growth and profitability while fostering a culture of continuous improvement.
Questions, Notes, and Highlights:
What’s your Lean origin story? How did you first learn about Lean, and what drew you to it?
Can you describe the initial transformation you led at Allied Signal, focusing on lead time reduction and flow?
How did you address resistance to change when implementing the model line at Allied Signal?
How did you ensure communication and involvement during that transformation?
Can you elaborate on the connection between safety and quality and how improving one supports the other?
How do you help leaders recognize that safety performance can improve significantly, even if zero injuries seems aspirational?
Have you seen Lean improve relationships between management and employees, especially where trust was broken?
What have you learned over time about the cultural and technical aspects of standard work?
How do you balance moving toward one-piece flow without overwhelming a system that isn’t ready for it yet?
How do you distinguish between a one-off performance issue and a sign of deeper trouble? How do you address it?
What qualities or mindsets do leaders need to lead both Lean transformations and long-term sustainment?
What’s the difference between leaders who are effective in transitions versus those who excel in sustaining improvement?
How does TBM Consulting evaluate the state of a plant during a turnaround? What does the assessment process involve?
Can you outline the four phases of turning around operations and share an example of how this approach was applied?
How do you prioritize improvement work when constrained by resources, like capex or time?
What warning signs indicate a plant is in trouble, and how do you help organizations prevent further decline?
How does TBM Consulting differentiate itself in helping businesses use operational excellence as a strategic advantage?
What insights have you gained about Lean from your career as both a practitioner and a consultant?
What’s the origin story of TBM Consulting, and how has its focus evolved over time?
How do you integrate leadership development into Lean practices for long-term success?
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. 

Achieving Healthcare Excellence: Insights from Jarvis Gray on Lean Six Sigma and Leadership

My guest for Episode #519 of the Lean Blog Interviews Podcast is Jarvis Gray, the Managing Director of The Quality Coaching Co. He offers more than 16 years of strategic planning, quality improvement, and operations leadership experience in the healthcare industry. 
Episode page with video, transcript, and more
Through his firm, The Quality Coaching Co., Jarvis and his associates help healthcare organizations foster cultures of system-wide quality improvement by offering customized Lean Six Sigma coaching, training, and certification programs centered on improving the quality of their care delivery services and health outcomes, eliminating waste and achieving cost reductions, and enhancing the patient experience.
He's the host of the Excellence in Healthcare podcast (where I have been a guest). His new book is MASTERING HEALTHCARE EXCELLENCE: A Leader’s Guide to Getting World-Class Results by Aligning People, Priorities, and Processes.
In this episode, we explored how to build a sustainable culture of excellence in healthcare by aligning people, priorities, and processes. We discussed the importance of integrating Lean Six Sigma principles with data-driven decision-making to improve patient outcomes and streamline operations.
Jarvis shared insights on establishing frameworks for healthcare excellence, including data cataloging and dashboarding, to track and leverage key metrics. We also delved into the evolving roles within healthcare quality improvement, the lessons learned from working closely with healthcare professionals, and the unique challenges of managing patient-centered processes. Lastly, we touched on his experience as a business owner, applying continuous improvement to his own consulting practice and the value of disciplined operations in achieving long-term success.
Questions, Notes, and Highlights:
What’s your origin story with quality, Lean Six Sigma, and healthcare?
How did Florida Power & Light's quality culture and Deming Award influence your approach?
What’s changed in the role of “management engineer” in healthcare since you entered the field?
When did you start the Quality Coaching Company, and what led to that decision?
What’s the central message or goal of your new book, Mastering Healthcare Excellence?
How do you use data in healthcare to achieve excellence, and what tools do you recommend?
What’s the healthcare excellence business model you promote in the book?
Can safety or quality serve as a competitive advantage in healthcare? Any examples?
What key lessons have you learned from healthcare professionals as an engineer?
Do you have an example of aligning people, priorities, and processes effectively in healthcare?
What improvements have you made in your own business from lessons learned in coaching?
For consultants and coaches, what small business coaching insights have helped you?
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. 

Breaking the MRP Insanity Trap: Jerry Wright on Lean Systems and Supply Chain Transformation

My guest for Episode #518 of the Lean Blog Interviews Podcast is Jerry Wright, author of the new book The Insanity Trap: What Your MRP Consultant Won't Tell You.
Jerry M. Wright, PE, MBA, is an accomplished operations executive and teaching professional with over 39 years of experience in the manufacturing and service sectors. 
His extensive career spans various industries, including aerospace, consumer goods, healthcare, medical devices, diagnostics, and industrial sectors, where he has held leadership roles in engineering, operations, quality assurance, and operational excellence (OpEx). 
He is an expert on taking businesses from MRP "insanity" to Pull Systems (Kanban) and driving operational excellence through the implementation of Toyota Production Systems (TPS/Lean) tools and methods.
He's a Master Black Belt and only the 7th person in the world to receive the Lean Gold Certification (LGC) from the joint alliance of ASQ, AME, SME, and the Shingo Institute.
In this episode, Jerry shares his insights and hard-earned lessons about the pitfalls and inefficiencies of Material Requirements Planning (MRP). Jerry reflects on his career, starting with his early Lean experiences at Kimberly Clark, where he encountered the challenges of forecasting, production scheduling, and the recurring "insanity trap" of MRP. He discusses the implementation of Kanban systems, the impact on inventory management, and how turning off MRP systems helped teams dramatically reduce shortages and excess inventory.
Through real-life examples, Jerry illustrates how companies can shift from traditional MRP-driven processes to more effective demand-driven and Kanban-based systems, leading to operational improvements, better employee engagement, and more reliable supply chains. The episode also touches on the psychology of change management, navigating the resistance from those invested in outdated systems, and how leadership can foster a more adaptive, efficient environment by embracing simplicity over complexity.
Questions, Notes, and Highlights:
What is your Lean origin story?
Were your parents open to Kaizen opportunities or suggestions from you as a child?
Was your first introduction to the "insanity trap" of MRP at Kimberly Clark?
Can you describe the challenges of dealing with MRP at Kimberly Clark?
What was Bill Holbrook's role when he suggested unplugging the MRP?
How did your team transition from MRP to Kanban, and what were the results?
Can you explain the issues with relying on forecasts and lead times in MRP systems?
What do you think about demand-driven MRP as an alternative?
Why do you think demand-driven MRP isn't more widely adopted?
How do you balance the risk of excess inventory versus lost sales?
How did Dell handle material constraints and lead time reduction when you were there?
How does Toyota manage its supply chain and production planning without relying heavily on MRP?
Can you talk about how Toyota's system recovers quickly from supply chain disruptions?
What was the origin of your book The Insanity Trap?
How can leaders and companies overcome the psychological barriers to changing their supply chain systems?
How do you help employees transition from roles like expediting to managing Kanban systems?
What are your thoughts on the promise of AI in demand forecasting and supply chain management?
Who is the target audience for your book?
What are your thoughts on supply chain planning versus execution in lean environments?
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.