Episode
Problem Solving XI: The Scientific Method, Toyota’s Approach to Problem Solving
What if the key to better problem-solving isn’t having the right answers, but learning how to ask the right questions? In this episode, we explore how Toyota applies the scientific method to problem-solving and continuous improvement—and why developing people who think like scientists is more valuable than simply teaching them to implement solutions. Drawing on…
Problem Solving X: Toyota Doesn’t Expect Frontline Workers to Solve Every Problem
One of the most widely accepted beliefs about the Toyota Production System is that frontline employees should be empowered to solve their own problems. But have we taken that idea too far? Empowering employees to solve problems is not the same as expecting them to solve every problem. In this episode, we challenge a common…
Genba Ikigai – The 16 Habits of Lean Leadership with Mark Forkun
Mark DeLuzio and Genba Ikigai author Mark Forkun discuss Lean leadership, problem-solving, culture, and sustainable performance.
Stop Copying Toyota’s Tools – Start Copying How Toyota Thinks
A Review: Decoding the DNA of the Toyota Production System
Lean at 8 Seconds – What NASCAR Pit Crews Can Teach Us About Lean
What can Lean leaders learn from a NASCAR pit crew, where three-tenths of a second can mean five car lengths and elite performance depends on five people executing as one? In this episode, we take the lessons from NASCAR’s pit road and translate them directly into Lean Operational Excellence. The surprising lesson is that world-class…
From Toyota to Danaher to Your Enterprise: Introducing Lean Horizons Academy
What if the Lean lessons that helped shape one of the world’s most respected business systems could be made available to everyone in your organization—anytime, anywhere, and in virtually any language? In this episode of Lean911, we introduce Lean Horizons Academy, a new approach to building practical Lean capability across the enterprise. Lean Horizons Academy…
The Danaher Business System – 12 Things I’d Do Differently
In this episode, I look back at the creation of the Danaher Business System and share 12 things I would do differently if I were building it today.
Be The Magic: 4 Phases to Transform Your Life with Manish Chauhan
What if the biggest transformation in your life begins with a simple shift in perspective—not from believing life is happening to you, but realizing it is happening through you? In this episode, we explore Be The Magic: 4 Phases to Transform Your Life by Manish Chauhan, a practical and deeply reflective guide that blends timeless…
25th Anniversary Episode: Lean Horizons’ Reflections – The Rise of Lean Theater
This episode explores the evolution of Lean over 25 years, highlighting challenges like credentialism, commercialization, and a shortage of experienced leaders, while emphasizing that the future of Lean depends on rediscovering its core principles rather than new tools.
How Hansei Builds Better Leaders
A CNC machine crashed on the shop floor. Nathan Corliss walked out as a young supervisor, angry and ready to blame the operator. What happened next became one of the most important leadership lessons of his career. Mark DeLuzio and Nathan talk about the moment that forced Nathan to confront his own behavior as a…
Replay: Standard Work
This is an unedited replay of a previous Lean 911 episode, originally published on January 13, 2023. We’re bringing it back because the issue still causes Lean transformations to stall, drift, or flatline. One of the most misunderstood parts of Lean, Standard Work, is often dismissed as unnecessary. So many companies contend that they are…
The Six Sigma Hysteria
In this episode, we dive into the rise, dominance, and controversy surrounding Six Sigma — the corporate improvement system that promised near-perfect quality and became a management obsession across America. From Motorola’s statistical revolution to Jack Welch’s aggressive rollout at General Electric, Six Sigma evolved from a useful quality tool into what some critics call…