177 episodes

Start each workday with digestible nuggets on the benefits of running a lean organization. We cover 5 topics in 5 days in about 5 minutes.

1. Leadership- Discover key concepts for successfully leading your organization during its lean transformation.
2. Culture/Intrapreneurship- Learn how to support your intrapreneurs, those who are driving change within your organization.
3. Lean Topics- Still catching on to lean principles and methodologies? We’ll help you with the basics and advanced topics.
4. Industry 4.0- Learn how smart manufacturing, smart factories, the Industrial Internet of Things (IIoT), and more will change the face of business.
5. Interviews- Hear from others that are on their lean journey and learn their secrets to success!

Learn more about American Lean at www.americanlean.com
Tom Reed can be reached at tom@americanlean.com

American Lean Weekday: Leadership | Lean Culture & Intrapreneurship | Lean Methods | Industry 4.0 | Case Studies Tom Reed: Lean Enthusiast & President of American Lean

    • Management

Start each workday with digestible nuggets on the benefits of running a lean organization. We cover 5 topics in 5 days in about 5 minutes.

1. Leadership- Discover key concepts for successfully leading your organization during its lean transformation.
2. Culture/Intrapreneurship- Learn how to support your intrapreneurs, those who are driving change within your organization.
3. Lean Topics- Still catching on to lean principles and methodologies? We’ll help you with the basics and advanced topics.
4. Industry 4.0- Learn how smart manufacturing, smart factories, the Industrial Internet of Things (IIoT), and more will change the face of business.
5. Interviews- Hear from others that are on their lean journey and learn their secrets to success!

Learn more about American Lean at www.americanlean.com
Tom Reed can be reached at tom@americanlean.com

    Replay- MD Engineering Uses Lean to Improve Cash Flow to Grow

    Replay- MD Engineering Uses Lean to Improve Cash Flow to Grow

    One of the key elements on my American Lean Weekday podcast is the weekly interviews that I conduct with companies on their Lean Journey. These companies are from various industries and are all different sizes. I have interviewed leaders from family-owned businesses to multi-national organizations. These are keynotes from a conversation with MD Engineering.
    lean manufacturing (http://www.mdengineeringonline.com/lean-manufacturing/), they manufacture and assemble tight tolerance and short lead-time projects based on customers’ demands.
    These are some key points taken from my interview with the Chief Operations Officer Ryan Cortes.
     MD began its Lean journey in 2009. They have been aggressively pursuing change for eleven years".
     "One of the things that we learned early on was the principles that Lean talks about were true! We ended the year with great sales dollars but had no cash in the bank. It was all tied up in inventory!"
     "If you have a dollar in cash you can spend it if you have a dollar tied up in inventory- you can't do anything with it. Cash is king in a small business."
    "Lean absolutely applies in a machine shop setting. I can't think of a company that Lean is more applicable in than a machine shop."
    I would get some training as you begin your Lean journey. I don't think the theory sinks in at first for the average person.
    I wasn't optimistic about what Lean could do for us. I was trying to appease a customer. But as I learned more about it and MD Engineering embraced it, there is no doubt we would not have enjoyed the growth that we have had without a Lean transformation.
     To hear Ryan’s interview please join us on the podcast at Americanlean.com (http://www.americanlean.com/podcast) episode forty-seven.
    As always, it is an honor to serve you and I hope that you and your company are getting better every day!
    Rate and Review Here (http://getpodcast.reviews/id/1499224100)

    More show notes are here (https://americanlean.com/blog/md-engineerings-lean-journey-helped-them-free-cash-to-grow/)
    Buy (https://www.amazon.com/dp/1645162818) the Lean Game Plan

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    • 13 min
    Mercedes Benz is taking a Holistic Approach to Industry 4.0

    Mercedes Benz is taking a Holistic Approach to Industry 4.0

    I’m always searching for articles to gather information to share with you regarding Industry 4.0 and other topics. Two weeks ago I mentioned how Porsche and Bugatti are 3D printing brake calipers and replacement parts for their cars. This week, I want to share how Mercedes Benz is taking a holistic approach to Industry 4.0 technologies to integrate all their plants together and the savings they expect.
    It is called MO360 (Mercedes Benz Car Operations) 360. MO360 is a suite of software applications that gathers and integrates real-time information to provide information to operators across a simple user interface. About 30 facilities worldwide are taking advantage of parts of the software.
    What does Mercedes hope to gain?
    1. Rapid software sprintsThey use cross-functional teams with production and IT support to develop the software ecosystem. According to Daimler CIO- Jan Brecht- “Organizational boundaries no longer have a role to play. All teams systematically utilize continuous feedback from production to optimize and enhance digital tools.”
    The sprints are two weeks long and focus on adding perceptible user benefits. According to Brecht “For software engineering in the field of production, that is an absolute record.”
    2. Paperless manufacturingMercedes just opened a brand new factory in Sindelfingen, Germany. It is referred to as factory 56 and will the testbed for everything Mercedes does regarding MO360.
    The factory is designed with 5G mobile technology built-in so that all sensors, equipment, and systems can communicate with each other. The system knows by the inch the location of each vehicle in the factory.
    Operators use a digital information system that gives them the information they need to work on the vehicle in front of them. All inspection forms are completed digitally. It’s estimated this will save 10M tons of paper annually!
    3. Real-time quality informationMercedes is using a system called Quality Live inside of MO360 that gives employees push-button real-time quality status of any vehicle. Any non-conformances are taken care of before the car reaches the end of the assembly line.
    MO360 monitors quality issues and using Artificial Intelligence, offers process improvements based upon analyzing the quality data.
    4. KPI’sThe MO360 system provides up to the minute KPIs (Key Performance Indicators) so production leaders can react to what is happening on the production line. Adjustments to schedules, sequences, etc. are shared instantly with suppliers.
    5. TPMWhen all plants throughout the world connect to MO360, the system will monitor and learn from maintenance occurrences. The system will offer predictive maintenance and plan the maintenance outage for an optimal time.
    As an example, as the system learns that a motor driving a conveyor belt fails after 50,000 hours, it can schedule replacements throughout the system and keep the correct number of motors on hand for replacement. This helps save MRO spend on this huge organization.
    I hope enjoyed learning how Mercedes Benz is taking a holistic approach to Industry 4.0! I know I like bringing you this information.
    As always, it’s an honor to serve you, and I hope this helps you and your organization get a little better today.
    Rate and Review Here (http://getpodcast.reviews/id/1499224100)


    More show notes are here (https://americanlean.com/blog/mercedes-benz-is-taking-a-holistic-approach-to-industry-4-0/)
    Buy (https://www.amazon.com/dp/1645162818) the Lean Game Plan

    Follow me on Linked In (https://my.captivate.fm/www.linkedin.com/in/tomreedamericanlean)

    • 5 min
    Keep Your Lean Journey Moving Forward

    Keep Your Lean Journey Moving Forward

    It might seem like the time to stop, but it is more important than ever to keep your lean journey moving forward with these four tips!

    • 4 min
    Four Guidelines for Supporting Your Lean Intrapreneurs

    Four Guidelines for Supporting Your Lean Intrapreneurs

    The employees that are working as lean coordinators, six sigma black belts, etc are really intrapreneurs. Learn how you can support them for success!
    Provide a defined time frame for participation
    Have clearly defined goals for the business
    Choose wisely and provide training
    Measure and adjust as necessary
    Learn how you can support these intrapreneurs!
    Rate and Review Here (http://getpodcast.reviews/id/1499224100)


    More show notes are here (https://americanlean.com/blog/how-to-improve-every-day-with-kata/)
    Buy (https://www.amazon.com/dp/1645162818) the Lean Game Plan

    Follow me on Linked In (https://my.captivate.fm/www.linkedin.com/in/tomreedamericanlean)

    • 5 min
    The Importance of a Management System to Support Servant Leaders

    The Importance of a Management System to Support Servant Leaders

    Servant leadership is often associated with successful Lean innovations. While many organizations think implementing Lean is deploying a known set of tools, it is truly about changing your organization’s culture. One way to change your culture is to develop and support servant leaders.
    Robert Greenleaf is known as coining the phrase “servant leadership” in 1970. Like Toyota, he developed some frameworks that can apply to different organizations but not be directly copied.
    Key discoveries that Robert Greenleaf identified are that “servant leadership is a lifelong journey that includes self-discovery, a desire to serve others and a commitment to lead.”
    Servant leader characteristics that he identified is that they are:
    Trustworthy
    Self-aware
    Humble
    Caring
    Visionary
    Empowering
    Relational
    Competent
    Good stewards
    Community builders
    These characteristics sound amazing but are they possible in today’s department driven culture? Some organizations drive a scarcity mindset amongst their leaders. This leaves leaders lobbying for scarce budget dollars.
    A key element that organizations need in place to support servant-leadership and drive employee engagement is alignment. If the leadership team doesn’t establish a decision-supporting Management System, it is hard to have alignment. Without a Management System as a True North, the decision directing framework is missing.
    With a well-defined Management System in place, everyone in the organization understands the business priorities. Aligning everyone’s actions to a common Management System eliminates confusion.
    Having leaders ask themselves if what they are doing supports the Management System, they can become more humble, relational, caring and empowering.
    While this will not be an overnight transformation- remember Greenleaf suggests it is a lifelong journey- there are some key questions you should be regularly asking yourselves as leaders.
    1. Are my actions helping my employees learn and grow?2. Are my actions helping my employees become more autonomous?3. Are my actions helping my employees become servant leaders themselves?These three questions are a great starting point for personal reflection on becoming a servant leader. What I have observed over my career is the companies that use a published Management System are better at supporting Servant Leaders.
    The leaders are guided by the principles of the Management System. The decision-making process becomes quick and consistent. This allows leaders to focus their efforts on providing increased employee support. When employees feel supported their engagement increases, turnover decreases, and the company harnesses the power of everyone making them a force to be reckoned with.
    Let me know in the comments some of the best examples of Servant Leadership that you have come across. You can listen to the podcast at American Lean Weekday podcast episode three.ate and Review Here
    Rate and Review Here (http://getpodcast.reviews/id/1499224100)


    More show notes are here (https://americanlean.com/blog/four-tips-to-identify-leadership-potential/)
    Buy (https://www.amazon.com/dp/1645162818) the Lean Game Plan

    Follow me on Linked In (https://my.captivate.fm/www.linkedin.com/in/tomreedamericanlean)

    • 5 min
    Industry 4.0 IOT with Factory Wiz

    Industry 4.0 IOT with Factory Wiz

    Rate and Review Here (http://getpodcast.reviews/id/1499224100)


    More show notes are here (https://americanlean.com/blog/four-tips-to-identify-leadership-potential/)
    Buy (https://www.amazon.com/dp/1645162818) the Lean Game Plan

    Follow me on Linked In (https://my.captivate.fm/www.linkedin.com/in/tomreedamericanlean)

    • 16 min

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