The Improvement Nerds Podcast

thegreendotconsultinggroup
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Join us as our guest share with us their greatest passions and the things that make them nerdy. All with the hope of chaning the world.

  1. JAN 23

    S2 E17 - The Magic Behind the Line: Lean Thinking at Disney (Part 2)

    In this Part 2 conversation, we go deeper into how Disney applies Lean thinking across the park — often in ways guests never consciously notice. We unpack: How Disney designs queues to create flow and reduce the feeling of waiting Mistake proofing and layered safety systems beyond the obvious ride checks How vertical space, theming, and atmosphere shape the “experience before the experience” Cast member empowerment, service recovery, and magical moments How the Disney app quietly load-levels guests, reduces friction, and reshapes park flow What healthcare, manufacturing, and service organizations can learn from Disney’s approach If you enjoy spotting Lean in the Wild, this episode is packed with real-world examples you can apply well beyond the parks. 🎢 Buckle up, check the yellow strap, and let’s keep waging war on bad process. 00:00 – Intro & Why Part 2 Why the Disney conversation deserved another round 02:30 – Queue Design & “The Experience Before the Experience” How Disney makes waiting feel like part of the attraction 07:45 – Vertical Queues & Using Space Differently What other industries can learn from Disney’s use of vertical space 13:40 – Healthcare & Waiting Room Design Applying queue thinking beyond theme parks 18:45 – Mistake Proofing 101 (Jidoka & Poka-Yoke) Soft vs. hard error proofing explained 24:30 – Ride Safety & Layered Error Proofing Why Disney builds redundancy into safety systems 31:10 – Food Allergies & Operational Safeguards Error proofing that protects guests without slowing flow 37:45 – Trash Cans, Cleanliness & Hidden Safety Systems Why cleanliness is also a safety strategy 43:50 – Load Leveling & Cast Member Flexibility How Disney staffs dynamically as crowds change 50:20 – Standard Work & Shift Handoffs What those quiet paper handoffs might really represent 55:40 – Empowerment & Service Recovery Magical moments, autonomy, and long-term loyalty 1:03:10 – The Disney App & Flow Through Technology Wait times, mobile ordering, photos, and guest self-service 1:12:30 – Continuous Improvement in the Parks How Disney keeps evolving without losing its core experience 1:18:30 – Lightning Round & Closing Thoughts Lean sensei Walt Disney, transformation, and what’s next   #ImprovementNerdsPodcast #LeanInTheWild #ContinuousImprovement #ProcessImprovement #LeanThinking #DisneyOperations #QueueDesign #MistakeProofing #CustomerExperience #ServiceDesign #OperationalExcellence #LeanLeadership #Flow #DisneyNerds #WagingWarOnBadProcess #BehindTheMagic

    51 min

  2. 12/08/2025

    S2 E16 - Tom West & Mark Ryan - Visual Management That Actually Works - Our Disney Experience

    S2 E16 - Tom West & Mark Ryan - Visual Management That Actually Works - Our Disney Experience 🎙️ Episode Description:  Visual Management - From Strategy Development to Ride Lines at Disney  In this episode of The Improvement Nerds Podcast, Tom and Mark go full nerd on one of their favorite Lean topics: visual management — and then take that lens all the way to Disneyland. We start by unpacking why effective visual management is more than hanging a board on the wall. At its best, visual management creates a true line of sight between strategy and the work, making goals, problems, and progress visible and actionable for frontline teams, leaders, and executives alike. From there, we take Lean out into the wild. While walking the park at Disneyland, we observe visual management in action — from wait-time boards and queue design to ticketing, security flow, parade setup, and even pin trading. Along the way, we uncover real-world examples of PDCA, Little’s Law, flow, and customer experience design hiding in plain sight. If you’ve ever looked at a wall of charts and post-its and wondered “Is this actually helping anyone?” Or stood in a theme park line thinking “This flow could be so much better,” this episode is for you. So pull up a chair, eavesdrop on the conversation already in progress, and join us as we wage war on bad process. ⏱️ Episode Timestamps 00:00 – Intro Why visual management is more than a board on the wall 02:10 – What Visual Management Is Really For Creating true line of sight between strategy and frontline work 06:15 – When Visual Boards Fail How boards turn into clutter, noise, and decoration 10:45 – Designing Visuals That Get Used Clarity, flow, and information people can act on 15:30 – Taking Lean Thinking to Disneyland Why a theme park reveals powerful process lessons 18:40 – Wait Time Boards vs. Queue Distractions Separating critical information from entertainment 22:55 – Arrival, Ticketing, and Security Flow Where visual management could reduce confusion and anxiety 27:30 – Movement, Flow, and Perceived Wait Time Why moving makes waits feel shorter 31:20 – Little’s Law in the Wild Estimating wait times through flow and capacity 35:45 – Could AI Improve Wait Time Accuracy? Exploring real-time data and flow visibility 39:50 – Pin Trading as PDCA How a cardboard box became a strategy experiment 46:10 – Strategy Through Small Steps Why iteration beats big-bang execution 51:30 – Visual Management During the Parade Tape, signals, standard work, and crowd flow 56:45 – Learning to See Everywhere Why Lean makes you more curious — even on vacation 1:00:30 – What Disney Really Sells Experience, escapism, and customer value 1:04:45 – Measuring Happiness Active vs. passive voice of the customer 1:08:20 – Final Reflections How visuals shape behavior, flow, and experience 1:10:15 – Outro Key takeaways and closing thoughts   If you enjoyed this episode: 👍 Like and subscribe for more Improvement Nerd content ⭐ Leave us a review to help other nerds find the show 🔄 Share this episode with a colleague who loves Lean or process improvement 💬 Drop us a note with examples of visual management you’ve spotted out in the wild And as always — remember to leave your processes better than you found them.   #LeanThinking #VisualManagement #ContinuousImprovement #ProcessImprovement #OperationalExcellence #CustomerExperience #Disneyland #GuestExperience

    43 min

  3. 11/07/2025

    S2 E15 - Jim Benson - Beyond the Board - Making Work More Human

    📖 Description In this episode of the Improvement Nerds Podcast, host Mark Ryan welcomes back Jim Benson, creator of Personal Kanban and co-author of The Collaboration Equation. If you caught their first conversation, you know it was a deep dive into how visualizing work and limiting WIP can transform not just productivity—but how we think and feel about our work. In this follow-up, Jim and Mark go beyond the board, exploring what it truly means to make work more human. Together they discuss how to connect strategy to action, align teams across levels, and navigate change through respect, visualization, and collaboration. From Kanban to Obeya, from X-Matrices to leadership maturity, this is an episode for every improvement nerd who believes that better processes start with better people. So grab your notebook and join us as we wage war on bad process—and remember to leave your processes better than you found them. 🕒 Episode Timestamps 00:00 – Intro Mark welcomes Jim Benson back to the show and recaps their first conversation on Personal Kanban. 02:15 – What Is Personal Kanban? Jim breaks down the two rules—visualize your work and limit WIP—and how they lead to focus and flow. 07:30 – Cognitive Overload & the Zeigarnik Effect How unfinished work clutters the mind—and why managing flow frees creative energy. 10:40 – Visualizing the Work Ahead Why real-time visual systems like A3s, heat maps, and obeyas matter in a rapidly changing world. 15:50 – Obeya Explained The “war room” concept that connects strategy to frontline work—and brings teams together in real time. 22:10 – From Goals to Tactics Mark and Jim explore how GOST frameworks and X-Matrices help leaders see alignment across all levels. 29:45 – Flattening Power Distance How transparency builds trust and shifts executive conversations from reporting to real collaboration. 35:20 – Coaching Through Complexity Why maturity isn’t linear—and how great teams rebound, learn, and grow together. 47:00 – Lessons from Turner Construction A real-world case of leadership buy-in, respect for people, and small experiments that scale big change. 55:20 – Respect for People as the Foundation of Lean Why empathy and continuous improvement must coexist for real results. 59:45 – The Future of Lean and Agile What’s next for improvement as organizations shift, regress, and evolve. 1:06:10 – The Recipe Book Metaphor How blending frameworks—Lean, Agile, Six Sigma—creates better outcomes than rigid adherence. 1:10:25 – Navigating Power and ROI Jim’s advice to CI professionals on communicating value and protecting the craft. 1:17:15 – Staying Connected and Waging War on Bad Process Why the improvement community must stay united, adaptive, and people-focused. 1:21:00 – Outro Mark closes the conversation with a reminder: Keep improving, keep learning, keep nerding out, and remember to leave your processes better than you found them. 💡 Key Takeaways Visualization turns chaos into clarity. The best systems evolve around people, not the other way around. Maturity isn’t a destination—it’s the ability to adapt. Respect and curiosity drive sustainable improvement. True value is shown through engagement, not just metrics. 🔗 Connect with Jim Benson 🌐 modusinstitute.com 💼 Jim Benson on LinkedIn 📰 humaneWork.substack.com   Tags: PersonalKanban, Kanban, Lean, LeanSixSigma, Obeya, VisualManagement, ContinuousImprovement, OperationalExcellence, Agile, StrategyDeployment, HoshinKanri, XMATRIX, Flow, WIPLimits, SystemsThinking, PsychologicalSafety, ChangeManagement, ProjectManagement, WorkDesign, MakeWorkMoreHuman

    37 min

  4. 10/04/2025

    S2 E14 - Jim Benson - Make Work Visible, Make Work Better

    Title: S2 E14 - Jim Benson - Make Work Visible, Make Work Better Subtitle: Kanban and Lean Coffee to replace chaos with clarity Description: Jim Benson—co-creator of Personal Kanban, Shingo Prize winner, and co-founder of Lean Coffee—joins Mark to unpack how visual management and WIP limits reduce overload and create humane, effective teamwork. We trace the origins of Kanban for knowledge work, why “Done” should become “Learn,” and how a Seattle café experiment turned into a global pattern for better conversations and decisions. Chapters 00:00 Intro — why “make work visible” matters 01:05 Meet Jim Benson (Personal Kanban, Shingo Prize, Lean Coffee) 03:10 Punk rock → systems thinking → urban planning 05:25 Early real-time traffic/ITS and proto-Agile roots 07:40 When iterations weren’t fast enough: Kanban emerges 10:30 The pub napkin story & early knowledge-work Kanban 13:50 Personal Kanban: visibility for humans (not just tools) 16:45 Options → Doing → Done (and why “Done” should become “Learn”) 20:20 Columns, states, collaboration rules, and where work gets stuck 22:55 Why we limit WIP: flow vs. flood & cognitive load 26:20 Social debt, decision latency, and finishing with quality 30:00 PDCA on the board: Plan / Do / Study / Adjust in practice 33:15 Trello/Asana analogies and practical board setups 35:40 WIP slots/lanes and right-sized work 38:30 Human-centered Kanban and healthier team dynamics 41:10 The Lean Coffee origin story (Seattle café → worldwide) 45:00 Mechanics that matter: voting, timeboxes, continue/stop 48:05 Leveling power distance and creating equitable meetings 52:10 Using Lean Coffee for better leadership/team meetings 55:45 Kaizen Camp & Riot Games: from stuck to momentum 01:00:30 Community impact stories; what to try on Monday 01:04:30 Closing & how to stay connected Episode Highlights Visual management changes conversations—not just throughput WIP limits as guardrails against overload, rework, and hidden social costs Turning “Done” → “Learn” to make continuous improvement continuous Lean Coffee: simple rules that create equitable, productive discussions Guest Jim Benson — Co-creator of Personal Kanban; co-founder of Lean Coffee; co-founder, Modus Institute; Shingo Prize winner. #PersonalKanban #LeanCoffee #Lean #ContinuousImprovement #VisualManagement #WIP #Flow #Agile #ImprovementNerds

    36 min

  5. 09/04/2025

    S2 E13 - Mark Graban - Nerding Out on a Wide Range of Improvement Topics

    Mark Graban - A Wide-Ranging Nerd Out with Mark Graban Welcome back to the Improvement Nerds Podcast! In this episode, we nerd out with Mark Graban—award-winning author, consultant, speaker, and senior advisor to KaiNexus. Mark has dedicated his career to showing the world that Lean isn’t confined to factory walls. He’s the author of Lean Hospitals, Healthcare Kaizen, Measures of Success, and most recently The Mistakes That Make Us. Mark also hosts two long-running podcasts: Lean Blog Interviews (now in its 20th year!) and My Favorite Mistake, a storytelling favorite exploring how learning from failure drives growth. In our conversation, we cover: How Lean thinking found its way from factories to hospitals Why reacting less can actually make leaders more effective How psychological safety transforms improvement cultures The mistakes that truly make us stronger Why site visits, Japan study trips, and continuous curiosity fuel lasting improvement Whether you’re in healthcare, manufacturing, or just looking to sharpen your improvement mindset, this episode is packed with stories, lessons, and practical takeaways. 👉 If you’ve ever heard “that won’t work here,” this conversation is your counter-example. Timestamps 0:00 – Intro & catching up with Mark Graban 3:45 – Mark’s early career in manufacturing (GM, Dell, Honeywell) 9:20 – Transitioning Lean principles into healthcare 15:05 – The early days of Lean Hospitals & publishing Lean Hospitals 23:30 – The role of laboratories in Lean healthcare adoption 30:55 – Resistance to Lean in healthcare: “Patients aren’t cars” 37:10 – From Healthcare Kaizen to engaging frontline staff 44:40 – Measures of Success and Process Behavior Charts 54:15 – Why reacting less helps leaders lead better 1:02:20 – The “poop emoji” story and why dashboards mislead 1:11:05 – The power of psychological safety in improvement 1:20:15 – The Mistakes That Make Us and learning from failure 1:32:40 – Lessons from Toyota and Japan study trips 1:41:15 – What’s next for Mark Graban 1:44:30 – Where to find Mark online 1:46:00 – Wrap-up and key takeaways   #LeanThinking #LeanSixSigma #ContinuousImprovement #Kaizen #LeanHealthcare #MarkGraban #ImprovementNerdsPodcast #TheMistakesThatMakeUs #MeasuresOfSuccess #LeanHospitals #HealthcareKaizen #PsychologicalSafety #Deming #ProcessBehaviorCharts #LeanCulture #MyFavoriteMistake #LeanBlogInterviews #KaiNexus #ToyotaProductionSystem #LeanJapanTrip

    47 min

  6. 08/07/2025

    S2 E12 - Rebecca Ellis - Putting the Fun in Fungibility

    Title: S2 E12 - Rebecca Ellis - Putting the FUN in Fungibility, Beyond Cross-Training: The Nerdy Truth About Fungibility 🎧 Description: What if your org chart wasn't a cage, but a launchpad? In this episode of the Improvement Nerds Podcast, host Mark Ryan sits down with Dr. Rebecca Ellis—organizational design expert and Principal at AlignOrg Solutions—to unpack the concept of fungibility in modern workforce strategy. Dr. Ellis brings over 20 years of experience in healthcare, manufacturing, and finance to this deep dive on how flexible, compatibility-driven teams can boost employee engagement, agility, and innovation. From breaking down silos to creating systems that empower individuals to grow and pivot, this episode is packed with insight for leaders, HR pros, and CI nerds alike. If you're rethinking job roles, exploring agile org structures, or just tired of talent being trapped in fixed boxes, this one's for you. As always, we’re waging war on bad processes—so buckle up and get ready to nerd out. 📌 Timestamps: 00:00 – Intro: Waging War on Bad Process 01:20 – What is fungibility, really? 04:32 – Job descriptions vs. capability-based hiring 08:45 – Beyond cross-training: true talent portability 11:40 – Why fungibility matters in today’s workforce 14:20 – Generational shifts and the gig mindset 17:15 – Case study: Engineers & R&D silos 22:00 – The mindset and traits behind fungible talent 26:30 – Leadership challenges: resource hoarding vs. talent sharing 30:00 – Cultural blockers and breaking rigid role identities 34:10 – Fungibility’s impact on continuous improvement and burnout 38:00 – CI teams: tips for building fungible bench strength 41:55 – Piloting fungibility: All-in or all-out? 45:10 – Governance and avoiding chaos in flexible teams 48:40 – Strategic alignment: fungibility in agile & digital transformations 52:30 – Fractional work, rotations, and breeding future execs 56:50 – HRIS, AI, and internal talent marketplaces 1:01:30 – Big org vs. small org: Is fungibility scalable? 1:03:40 – Final advice: Shift the mindset, not just the model 1:05:00 – Where to find Dr. Ellis & closing remarks 🔗 Guest Info: Dr. Rebecca Ellis 📍 Website: https://alignorg.com 📍 LinkedIn: https://www.linkedin.com/in/rebecca-ellis-phd-ccmp/   #Fungibility #OrganizationalDesign #TalentMobility #ContinuousImprovement #AgileWorkforce #LeadershipDevelopment #HRStrategy #EmployeeEngagement #ImprovementNerds #LeanThinking #InternalMobility #ChangeLeadership #PodcastForLeaders #ProcessImprovement #FutureOfWork #HR

    39 min

  7. 07/09/2025

    S2 E11 - Laura Hayes - Making Accountability Make Sense

    In this episode of the Improvement Nerds Podcast, host Mark Ryan sits down with leadership coach and founder of Ground Rules Coaching, Laura Hayes, to unpack what real accountability looks like—and why it’s often misunderstood. From toxic blame culture to practical tools that drive responsibility, Laura helps us reframe accountability as a path to empowerment, not punishment. With certifications in Gallup StrengthsFinders, DiSC, Enneagram, The Five Behaviors, and Empathy Training, Laura brings a wealth of insight and heart to the conversation. Whether you’re a team leader, executive, or just trying to show up better at work, this episode is packed with actionable wisdom. 🔗 Laura’s Website: https://groundrulescoaching.com ⏱️ Timestamps 00:00 – Welcome & Introductions 02:24 – What accountability isn’t (and why people resist it) 06:55 – How to create a psychologically safe environment for real accountability 11:33 – The difference between expectations and agreements 16:50 – Addressing underperformance without shame 21:12 – The “Accountability Ladder” framework 27:45 – Tools to coach your team into ownership 34:10 – How empathy plays a key role in leadership 39:20 – Laura’s favorite client stories and breakthroughs 44:02 – Leadership self-awareness: where it starts 47:18 – Final thoughts and how to connect with Laura 🧠 Key Themes: Redefining accountability Tools for effective coaching conversations Creating agreements over assigning blame Why self-awareness is leadership’s secret weapon #ImprovementNerds #LeadershipDevelopment #Accountability #TeamCulture #ContinuousImprovement #LeanThinking #ProfessionalGrowth #GroundRulesCoaching #LauraHayes #ManagementTips #LeadershipPodcast #EmpathyInLeadership #PsychologicalSafety #PersonalGrowth #WorkplaceWellness

    38 min

  8. 06/04/2025

    S2_E10 - Chris Hayes - Wired for Excellence, Brain Science to Improve Culture & Change

    🎧 Podcast Title: Wired for Excellence: The Neuroscience of Change with Chris Hayes 🎙️ Guest: Chris Hayes, Author of Wired for Excellence 🔍 Episode Description: Don’t miss this fascinating deep dive into the brain science behind organizational change. In this episode of the Improvement Nerds Podcast, host Mark Ryan sits down with Chris Hayes, leadership expert and author of the upcoming book Wired for Excellence, to explore how neuroscience can help us lead better, think clearer, and build cultures that thrive. Chris explains how our brain’s threat and reward systems, including the amygdala and prefrontal cortex, influence everything from team performance to psychological safety. You’ll learn how leaders can use this knowledge to create environments that reduce resistance, increase engagement, and foster excellence at every level. Whether you're in Lean, Agile, Six Sigma, HR, healthcare, or education, this conversation will equip you with powerful new ways to lead through complexity and connect with your people. ⏱️ Timestamps: 00:00 – Intro: Why Neuroscience Matters in Change Work 02:45 – Meet Chris Hayes and Wired for Excellence 06:18 – What Happens in the Brain During Change 10:32 – The Role of the Amygdala and Threat Response 14:50 – Prefrontal Cortex: The Seat of Executive Function 19:43 – Psychological Safety and Cognitive Overload 24:17 – Brain-Smart Strategies for Leading Change 30:10 – Applications in Healthcare, Business, and Beyond 36:22 – How to Design with the Brain in Mind 42:40 – Final Reflections and a Preview of Chris’s Book 45:15 – Outro and Resources 📚 Resources & Links: Connect with Chris Hayes: chayes@getimpacts.com Hosted by Mark Ryan of The Green Dot Group 📢 Don’t Forget to Subscribe & Share If this episode sparked ideas or gave you an “aha” moment, hit subscribe, leave a review, and share it with your team or fellow improvement nerds. 🔖 Hashtags  #WiredForExcellence #NeuroscienceOfChange #OrganizationalExcellence #LeadershipDevelopment #ChangeLeadership #BrainBasedLeadership #ImprovementNerds #ChrisHayes #ProcessImprovement #LeanLeadership #PsychologicalSafety #ContinuousImprovement #ChangeManagement #NeuroscienceAndLeadership

    47 min
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About

Join us as our guest share with us their greatest passions and the things that make them nerdy. All with the hope of chaning the world.

Information

  • Creator
    thegreendotconsultinggroup
  • Years Active
    2020 - 2026
  • Episodes
    62
  • Rating
    Clean
  • Copyright
    © Copyright 2020 All rights reserved.
  • Show Website
    The Improvement Nerds Podcast