LEAN 911


Tune in as Mark DeLuzio, pioneer of the modern Lean movement answers all of your pressing Lean questions.

Recent Lean 911 Episodes

Why You Need a Lean Sensei

Mark talks with Lean Horizons’ Managing Director, Kevin Mathis, about why a company needs an experienced Lean Sensei (teacher). Learn Kevin’s 5 Points of a Lean Sensei as well as what Toyota has to say about this.

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Art Byrne – The Lean Answer Book

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO. This Lean Pioneer has led some of the most successful Lean turnarounds in brownfield environments. Art discusses his latest publication, “The Lean Answer Book” which documents the most common questions Art had been asked in over four decades regarding Lean Transformations.

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Mixed Model Production II – Implementation

Kevin Mathis, Managing Director of Lean Horizons Consulting, talks about how he created the first Mixed Model Production cell in Danaher. In this episode, Kevin discusses how to implement a mixed model cell as well as how it all relates to the fundamentals of the Toyota Production System, specifically, JIT, Standard Work, Heijunka, Kaizen and Jidoka.

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Mixed Model Production I – Introduction

In this episode of the Lean 911 podcast, Mark DeLuzio is joined by Kevin Mathis, a Managing Director at Lean Horizons. Kevin shares insights from his extensive experience, including pioneering mixed model production at Danaher’s Hennessey plant. The discussion covers the background of mixed model production, its challenges and benefits, the critical role of engaging…

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Destructive Lean “Leadership”

So many leaders have a gross misunderstanding as to how to get true, sustainable results using Lean principles and methodologies. When times get tough, many revert to headcount reductions, and many times, these reductions are in their Lean organization. Learn how to focus on the right things and avoid the well-deserved, however unfortunate, moniker that…

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On-Time Delivery Metrics – Measure to Promise or to Request Date?

Learn why measuring on-time delivery to REQUEST date is essential if a company truly believes in customer excellence. Mark DeLuzio dispels all of the excuses when companies refuse to measure OTD to request date.

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Chairs – To Sit or Not to Sit

Learn why chairs in a cell are detrimental to a good Lean cell design. Mark DeLuzio discusses the negative consequences of chairs from an SQDC perspective. (Safety-Quality-Delivery-Cost)

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Problem Solving VII – The Problem with Problem Escalation

Learn why problem escalation processes send signals to frontline associates that they are not qualified to solve problems over work that they are best suited to solve. This elitist approach demoralizes and demotivates employees when their engagement opportunities are stripped away from leaders who do not walk the talk when they preach that problems need to be solved at the lowest possible level in the organization.

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Mark DeLuzio principal architect of the Danaher Business System

Meet the Host of Lean 911


 Mark DeLuzio


Mark DeLuzio—known as a pioneer of Lean and the principal architect of the Danaher Business System—serves as a trusted advisor to senior leaders in global manufacturing organizations whose financial and operations metrics have flatlined. Leveraging his unmatched and inventive experience, Mark helps them think differently about how to optimize their approach system-wide.