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

Exploring Lean Product Development with Jim Morgan - Rivian's Former COO

My guest for Episode #515 of the Lean Blog Interviews Podcast is Jim Morgan, senior advisor at Lean Enterprise Institute and a board member at Adrian Steel. Jim’s most recent industry experience was as Chief Operating Officer at Rivian, an electric vehicle manufacturer.
Episode page with video, transcript, and more
He was previously a guest in Episode 109 back in 2011.
Before joining Rivian, Jim spent a little over ten years at Ford Motor Company. He began by leading the development of the Global Product Development System (GPDS). 
He then served the last nine years as Director of Global Body and SBU Engineering and Tooling operations, where he and his team contributed to the company’s historic, product-led revitalization under then-CEO Alan Mulally.   
Prior to Ford, Jim served as Vice President of Operations at Troy Design and Manufacturing (TDM), a tier-one global automotive supplier of engineering services, prototype tools, and low to medium-volume production parts and subassemblies. 
Jim holds a Ph.D. in Engineering from the University of Michigan, where his original research into Product Development won two Shingo Prizes for Research Excellence. In addition, he co-authored (with Professor Jeffrey Liker) the award-winning books The Toyota Product Development System (2006) and Designing the Future (2018). 
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We’ll dive into his incredible journey, from his time at Ford, where he led the development of their global product system, to his work at Rivian, helping to shape the future of electric vehicles. Jim shares valuable lessons learned along the way, especially around integrating lean principles into product and process development. We also talk about how embracing risk and learning from mistakes can fuel innovation.
Questions, Notes, and Highlights:
Lean Origin Story: What’s your lean origin story, and how did you get introduced to lean thinking?
Product Development vs. Production: Can you explain the difference between product development and production systems?
Rivian Involvement: How and when did you get involved with Rivian, and what drew you to the company?
Challenges at Rivian: What were the major challenges and opportunities as Rivian evolved from concept to production?
Recruiting for Rivian: How did you recruit talent for Rivian, and what was the mix of automotive and non-automotive experience?
Rivian’s Product Strategy: How did Rivian’s product strategy differ from other electric vehicle manufacturers like Tesla?
Culture Development: How did Rivian focus on building its own culture and operating system from the ground up?
Learning from Mistakes: How did Rivian’s culture embrace learning from mistakes, and how was that risk tolerance cultivated?
Ford and Alan Mulally’s Leadership: How did Alan Mulally’s leadership at Ford influence your thinking on surfacing and solving problems?
Board Involvement: What has your experience been like as a board member at Adrian Steel, and how does it differ from your previous roles?
LEI Learning Groups: Can you tell us about the LEI Product and Process Development Learning Group and how companies collaborate and learn together?
Designing the Future: What’s the central message of your book Designing the Future, and who is the target audience?
Agile and Lean Integration: How are you integrating agile and lean practices, especially in product and software development?
Key Topics:
Jim’s introduction to lean via The Machine That Changed the World.
Differences between lean product development and lean production systems.
Jim’s role at Rivian and the company’s approach to electric vehicle manufacturing.
Rivian’s unique culture and the importance of building the “Rivian Way.”
Challenges in launching new vehicles and managing diverse teams.
Importance of learning from failure and embracing risk at Rivian.
Lessons from Alan Mulally’s leadership style at Ford.
Jim’s board experience at Adrian Steel and how it differs from operational leadership.
Collaborative learning through LEI’s Product and Process Development Learning Group.
The integration of agile and lean principles for better hardware-software development alignment.
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. 

Coaching for Continuous Improvement: Lean Leadership Lessons from Sports with Hugh Alley

My guest for Episode #514 of the Lean Blog Interviews Podcast is Hugh Alley, an author and consultant. He divides his time between coaching senior operational leaders in continuous improvement, training front-line leaders in core supervisory skills, and designing industrial facilities. 
An industrial engineer, he has run three manufacturing and distribution firms, and a department in a government agency, teaching skills to over 1,000 front-line leaders. 
He has written two books: Becoming the Supervisor: Achieving Your Company's Mission and Building Your Team, and The TWI Memory Jogger.
He frequently speaks about supervision, quality, lean manufacturing, and Toyota Kata. From his home near Vancouver, Canada, he helps clients across North America.
In today's episode, we explore the power of TWI (Training Within Industry), its impact on building trust and improving workplace culture, and stories of real-world applications in manufacturing and sports. From reducing cycle times to fostering better leadership, this episode covers key lessons in Lean methodology. Tune in to hear about Hugh's Lean origin story and his experiences in applying Lean principles across various industries. Don't miss out on a thoughtful discussion that blends Lean, leadership, and even hockey!
Questions, Notes, and Highlights:
What kind of government agency did you work for?
How did you reduce lead times for occupational disease claims?
What is your lean origin story? Where, when, and why were you introduced to lean?
Was the word "Kaizen" used in your early lean experiences?
Is job relations typically the starting point in TWI, or does it depend on the culture?
What parallels do you see between sports coaching and leadership in the workplace?
How can you tell if a workplace problem is due to tactics, teamwork, or culture?
What role does continuous improvement play in sports teams' success, and can it happen game to game?
How do you see the role of fear in leadership and coaching, and what impact does removing a "bully" leader have on a team?
How can job instruction and job relations contribute to better workplace culture and performance?
How do you approach the challenge of hiring the right people and fitting them into a lean system?
How did TWI help one of your clients shorten training times and reduce bad product?
What opportunities do you see for companies to create "practice days" similar to sports teams?
How do you convince leaders to care about improving their supervisors' skills?
What role does a coach or leader play in creating the right context for their team to succeed?
What do you think makes a great player transition into a great coach?
How do you use the TWI model to break down jobs and help people learn faster?
What's your take on benchmarking against others in the industry?
How did you help reduce patient waiting times in a medical lab by aligning priorities?
Was Wayne Gretzky's coaching career unsuccessful, or did he just pick the wrong job?
How do you translate great skills into effective coaching, and how does TWI help with that?
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. 

Insights from 'Leading Excellence': Brad Jevons and Stephen Dargan on Adaptive Leadership

My guests for Episode #512 of the Lean Blog Interviews Podcast are two of three co-authors of the upcoming book “Leading Excellence: 5 Hats of the Adaptive Leader” - Brad Jeavons and Stephen Dargan.
Episode page with video, transcript, and more
Stephen Dargan
A diverse and inclusive, customer-centric, driven transformational leader with 20+ years of leadership experience spanning Australia and Europe. Stephen is a Shingo Institute Alumni, Shingo Facilitator and Examiner. He is a graduate of the Australian Institute of Company Directors and a certified Lean Six Sigma Black Belt.
Brad Jeavons
Brad Jeavons is a senior leadership coach focused on helping improve themselves and their organisations to create a better future economically, socially and environmentally for future generations. He is host of the Enterprise Excellence Podcast and Community and author of the book Agile Sales: Delivering Customer Journeys of Value and Delight. Brad was a guest back in episode 416, June 2021.
In this episode, Brade and Steve share insights into the key concepts of adaptive leadership, including the importance of understanding individual team members, cultivating psychological safety, and the five essential leadership hats: Inspire, Train, Support, Coach, and Direct. Brad and Stephen also discuss real-life applications, the significance of leadership shadow, and the critical role of serving the growth of others to drive organizational excellence.
Questions, Notes, and Highlights:
What are some factors contributing to low employee engagement?
Can you elaborate on the concept of the leadership shadow and its impact?
What behaviors help cultivate psychological safety and engagement?
What does it mean to be a leader who serves, and why is it important?
How can leaders develop the ability to be adaptive or situational?
What are the five hats referenced in the subtitle of your book?
Why is controlling emotions crucial for leaders, and how can they improve this skill?
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. 

Flow Engineering in Action: Insights from Authors Steve Pereira and Andrew Davis

My guests for Episode #512 of the Lean Blog Interviews Podcast are Steve Pereira and Andrew Davis, authors of the new book Flow Engineering: From Value Stream Mapping to Effective Action.
Blog post with video, transcript, and more
Steve Pereira has spent over two decades improving workflow across various organizations. His experience spans tech support, IT management, platform and infrastructure engineering, product management, and serving as a founding CTO for an enterprise SaaS company. Currently, he is the CEO of Visible Consulting, COO of the Value Stream Management Consortium, and co-founder of the Flow Collective.
Andrew Davis is the Chief Product Officer at AutoRABIT and the author of "Mastering Salesforce DevOps." With a background as a Salesforce architect, developer, and product leader, Andrew focuses on the human side of software development. He spent 15 years as a Buddhist monk, teaching meditation and personal transformation, and now studies the intersection of business, technology, and psychology through systems thinking.
In this episode, we discuss the principles of flow engineering, the importance of psychological safety in process improvement, and their experiences in writing the book. We also dive into their personal journeys, inspirations from industry giants like Deming and Goldratt, and the challenges and lessons learned in collaborative work. Stay tuned for a deep, insightful conversation on enhancing workflows and fostering a culture of continuous improvement.
Questions, Notes, and Highlights:
Can you discuss the relationship between making mistakes and learning from a Buddhist perspective, Andrew?
Why do you resonate with figures like Deming, Goldratt, and Ackoff in your improvement work, Steve?
How did you two end up collaborating on the book?
Did you apply flow engineering concepts to the development and writing of the book together?
How did the process of writing the book evolve over time?
What lessons did you learn about collaboration and flow from writing this book?
How does psychological safety impact value stream mapping and flow engineering?
How do you involve workers in process design to avoid negative perceptions of imposed processes?
What challenges did you face in maintaining a regular cadence of work while writing the book?
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. 

Paul Critchley on His Upcoming New England Lean Summit and More

In this special live-streamed bonus episode of the Lean Blog Interviews podcast, host Mark Graban is joined by Paul Critchley for an impromptu experiment in recording a live podcast. The episode begins with a brief introduction and a discussion about the decision to try a live format.
Paul Critchley, a seasoned Lean consultant, shares his background, detailing his journey from a mechanical engineer in the automotive industry to his current role as a Lean practitioner and consultant. He highlights his experiences working with Toyota and Pratt & Whitney, emphasizing the practical application of Lean principles in various industries, including aerospace.
Summit info: https://newenglandleanconsulting.com/summit/ 
The conversation then shifts to Paul's upcoming event, the New England Lean Summit, scheduled for September 12-13, 2024, in Cromwell, Connecticut. Paul discusses the summit's agenda, which includes workshops, sessions, and a Lean Happy Hour. He expresses his excitement about bringing together Lean professionals from diverse industries to foster learning and networking in a fun and engaging environment.
Paul also introduces the New England Lean Collaborative, a member-based organization aimed at building a community of Lean practitioners in the New England region. He explains the collaborative's activities, such as book clubs, site tours, and resource sharing, designed to facilitate continuous learning and improvement.
The collaborative: https://newenglandleanconsulting.com/the-nelc/ 
The episode wraps up with Mark and Paul addressing a viewer's question about implementing Lean practices in small companies with limited resources. Paul advises starting small, focusing on incremental improvements, and maintaining momentum through continuous, manageable changes.
 
Throughout the episode, Paul emphasizes the importance of creating a psychologically safe environment for learning and experimenting with Lean practices, highlighting the benefits of fun and engagement in the process. The episode concludes with a reminder of the event details and an invitation for listeners to join the New England Lean Summit and Collaborative.
 
00:01:24: Guest Introduction - Paul Critchley
 
00:03:00: Paul's Career Background
 
00:03:39: Discussion on Practicing Lean - https://practicinglean.com/
 
00:05:02: New Projects and Endeavors
 
00:05:29: New England Lean Summit Introduction
 
00:06:08: Details about the New England Lean Summit
 
00:07:04: Summit Logistics and Activities
 
00:09:02: Lean Happy Hour Concept
 
00:10:00: Hope for Future Annual Events
 
00:10:19: Overview of the New England Lean Collaborative
 
00:11:00: Functioning of the Collaborative
 
00:11:42: Membership Benefits and Activities
 
00:12:48: Discussion about Industry Participation
 
00:14:23: Lean Tools and Concepts
 
00:15:23: Connection with Bob Rush and Workshop Details
 
00:16:36: Fun Activities Planned for the Summit
 
00:17:01: Emphasizing fun and networking at the summit
 
00:17:39: Lessons from Pascal Dennis at Toyota
 
00:18:31: Incorporating a DJ at the conference
 
00:19:48: Creating a relaxed and engaging atmosphere
 
00:21:02: Unique conference experiences
 
00:22:00: Opportunities for

Failing Forward: Sam Yankelevitch on Lean, Communication, and Innovation

My guest for Episode #511 of the Lean Blog Interviews Podcast is Sam Yankelevitch, a distinguished global operations executive who has dedicated his career to advancing Lean principles, effective communication, and innovative problem-solving. Sam's journey began with managing international projects and optimizing processes in various industries. His expertise and passion for continuous improvement have made him a sought-after speaker, workshop trainer, and corporate coach.
Episode page with video, transcript, and more
Sam is one of the speakers and facilitators at the upcoming Global Lean Summit Event, being held in Indiana this September.
Since 2014, Sam has leveraged his vast knowledge by producing popular online courses that have reached over 500,000 students worldwide. His contributions to LinkedIn Learning include highly-regarded courses such as "Root Cause Analysis" and "Improve Communication Using Lean Thinking." Sam's ability to distill complex concepts into actionable insights has earned him a dedicated following among professionals seeking to enhance their skills.
In addition to his educational endeavors, Sam recently ventured into fiction writing with his debut book, An Interview with Failure. This unique narrative explores the lessons learned from setbacks and the value of embracing failure as a stepping stone to success.
Before establishing himself as an influential educator and author, Sam held several key positions, including Vice President and General Manager at a German-based automotive supplier and President and CEO of Ideace, Inc., an international manufacturer and exporter. His diverse background and hands-on experience provide a rich foundation for his teachings.
Sam holds an Industrial Engineering degree and an Executive Master's in Financial Management, further solidifying his expertise in operational excellence and strategic leadership.
In this episode, we discuss the pivotal role that effective communication plays within the framework of lean thinking. We also explore how clear, concise, and consistent communication can significantly enhance problem-solving capabilities, streamline processes, and foster a culture of continuous improvement. Sam shares his insights on the common communication pitfalls that organizations face and offers practical solutions to overcome these challenges using lean methodologies.
Additionally, we preview Sam's upcoming workshop at the Global Lean Summit, where he will be leading a session on lean communication. This workshop aims to equip participants with hands-on tools and techniques to improve communication within their organizations. Attendees will learn how to adapt lean principles to enhance clarity, reduce misunderstandings, and ensure that everyone in the organization is on the same page, thereby driving better results and fostering a more collaborative work environment.
Questions, Notes, and Highlights:
Tell us about the workshop you're doing at the Global Lean Summit.
What are some core communication problems that Lean thinking addresses?
Can you explain the concept of operational definitions from Dr. Deming?
How can Lean methods improve communication in an organization?
What's your lean origin story?
How did your international experience influence your Lean approach?
What were some challenges you faced when implementing Lean in the automotive industry?
What advice would you give to someone leading a Lean transformation?
How do you reframe failure as a learning opportunity?
Can you tell us about your book, "An Interview with Failure"?
How do you build trust in a coaching relationship?
What's the importance of commitment conversations in leadership?
How do you handle the word "accountability" in a positive way?
How does communication serve as a precondition to quality?
What can leaders do to improve their communication skills on the shop floor?
What are the benefits of standard work and 5S in a high-mix, low-volume environment?
How can Lean tools like Smed and Andon be applied to communication processes?
What lessons have you learned about leading and motivating people throughout your career?
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. 

Karen Martin on the Power of Mistake Proofing in Lean Management

My guest for Episode #510 of the Lean Blog Interviews Podcast is Karen Martin, Founder and CEO of TKMG and TKMG Academy, appearing for the fifth time.
Episode page with video, transcript, and more
She is the author of books including The Outstanding Organization, Clarity First, and Value Stream Mapping.
In this episode, we discuss mistake-proofing in lean practices, exploring its significance in various industries. The conversation begins with a light-hearted discussion about the "five-timers club" and Mark's "ZERO hat" from the Patient Safety Movement Foundation, which symbolizes the goal of zero harm in healthcare.
Karen shares her extensive background in quality improvement and lean management systems, emphasizing the importance of building quality at the source. Drawing on the teachings of Dr. W. Edwards Deming and the Toyota Production System, Karen and Mark discuss the psychological impact of striving for zero harm, debating whether it is an inspiring goal or potentially demotivating.
The episode also explores real-world examples of organizations achieving zero harm and the cultural shifts required to reduce errors. Karen introduces the TKMG Academy and its comprehensive courses designed to enhance lean practices, including the new mistake-proofing course co-developed with Mark. Her passion for quality improvement and continuous learning shines through, offering listeners valuable insights into achieving operational excellence.
Questions, Notes, and Highlights:
Why is quality such a passion for you?
Why did you want to add the mistake-proofing course to the TKMG Academy catalog?
What are some common barriers to achieving zero harm in healthcare?
How do you differentiate between mistakes and errors?
How do you handle situations where the work system isn't at fault, but the individual continues to make mistakes?
Can you tell us more about the "slow work" movement?
What are your thoughts on final inspection versus quality at the source?
How do you address the challenge of maintaining standards in training and process design?
Could you elaborate on the spectrum of mistake-proofing from 100% prevention to error reduction?
How does the TKMG Academy help organizations with continuous improvement?
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. 

Bonus: Jared Thatcher on the Global Lean Summit 2024 Event

I'm very happy to be participating in Jared Thatcher‘s “Global Lean Summit” event this September in Indiana.
I'll be there to network and learn, which includes time visiting a Toyota Material Handling factory (an entire day!)
I'll be speaking and facilitating:
A workshop on Psychological Safety as a Foundation for continuous improvement
A learning session featuring Dr. Deming's “Red Bead Game“
A fun keynote talk on warning signs and mistake-proofing
Learn more and register
Here's a 13-minute conversation that I had with Jared about the event.

Leveraging Lean & AI in Optometry: Ankit Patel's Journey from Dell to Vision Care

My guest for Episode #509 of the Lean Blog Interviews Podcast is Ankit Patel, the founder of My Business Care Team, a BPO company providing services for optometrists, and co-founder with his wife Classic Vision Care, an optometry group in Atlanta.
Episode page with transcript and more
With a strong background in Lean methodology, Ankit has worked as a Lean consultant at Dell and the Cleveland Clinic, driving process improvements and coaching executives. 
He holds a Master's degree in Positive Organizational Development and a Bachelor's in Industrial Engineering. 
Recognizing talent acquisition challenges, Ankit partnered with a Filipino team to source skilled, cost-effective staff for various business functions. He now leverages AI for hiring and automation to optimize his optometry practice and BPO services, applying Lean principles to drive efficiency and growth.
In this episode, Ankit shares insights from his journey, starting as a lean consultant at Dell and the Cleveland Clinic, and transitioning into optometry, where he focuses on building patient relationships and enhancing processes through lean principles and AI technology.
Mark and Ankit discuss the challenges and opportunities of integrating AI in business processes, the importance of positive organizational development, and how appreciative inquiry can drive team alignment and engagement. Ankit also highlights the role of the Entrepreneurial Operating System (EOS) in managing small businesses and improving training and development with AI tools, offering valuable lessons for anyone interested in continuous improvement and innovative approaches in healthcare and beyond.
Questions, Notes, and Highlights:
What is positive organizational development, and how did you come to study it?
How did your experience at Cleveland Clinic influence your involvement in your current business?
How do you balance focusing on optometry with the potential to expand into other medical practices?
How do you prioritize where to use AI in your processes without falling into the trap of using it because it's trendy?
Can you share an example of improving a process before thinking about automating it with AI?
How rapidly is AI technology advancing, and how does that impact your ability to adjust its use in your business?
How do you see AI tools facilitating faster PDCA or PDSA cycles in continuous improvement practices?
What led you to the positive psychology approach, and how does it differ from traditional organizational development?
How do you apply appreciative inquiry in your work, and what impact does it have on team alignment and engagement?
Can you discuss the origin and growth of your new business involving AI and BPO for optometry?
What role does EOS (Entrepreneurial Operating System) play in managing your business?
How do you evaluate the effectiveness of training and development using AI tools?
How do you communicate your practice's focus on building patient relationships in your marketing and branding?
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. 

Psychological Safety in Lean Leadership: Insights from Mike Hoseus and Toyota’s Culture

My guest for Episode #508 of the Lean Blog Interviews Podcast is Mike Hoseus, Executive Director of the Center for Quality People and Organizations and President of Lean Culture Enterprises.
Episode page with video, transcript, and more
He supports organizations in their lean journey, focusing on leadership and cultural aspects of the lean transformation. He is an adjunct professor with the University of Kentucky's Center for Manufacturing.
Michael Hoseus developed his TPS skills at Toyota Motor Manufacturing Kentucky, where he worked at the General Manager level in both Production and Human Resources, being mentored by his Japanese sensei. His Toyota process experience includes production, engineering, maintenance, safety, personnel, employee relations, benefits/payroll and training and development.
He learned first-hand how Toyota's success hinges on integrating their production and human systems to create the Toyota Way. 
He's co-author, with Jeff Liker, of Toyota Culture: The Heart and Soul of the Toyota Way — which received the Shingo Publication Award in 2009
In this episode, Mike shares his extensive experience with Toyota, where he developed his TPS skills at TMMK in Georgetown, Kentucky. We take a deep dive into key topics such as the importance of psychological safety in lean leadership, the origins of the andon cord, and how to build a high-performance culture.
Mike discusses his journey from Toyota to helping other organizations with lean transformation, emphasizing the critical role of leadership in fostering a culture of continuous improvement. He shares insights on problem identification and problem-solving, the significance of respect and trust, and the intentional development of a lean culture.
Join us for this engaging conversation with valuable lessons and stories from Mike's career. Don't miss out on the chance to learn from one of the leading experts in lean culture and transformation.
Mike is also organizing a Kentucky learning tour, “High-Performance Culture and Lean Leadership,” from October 15 to 17… I'll be there and am very much looking forward to it. Use code GRABAN to save $500.