Lean 911

Mark DeLuzio
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The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.

  1. 1 NIS

    Standards Written in Blood - There May Be No Second Chance

    Lean management teaches that standards are the foundation of safety, quality, and improvement. In aviation, those standards take the form of checklists, redundancies, procedures, and strict cockpit protocols designed to prevent human error. In this episode, we examine the tragic aircraft accident that claimed the life of Greg Biffle and his family, and what it reveals about the danger of ignoring established standards. Reports indicate that critical procedures were bypassed—checklists weren't followed, and an unqualified individual was allowed into the cockpit. In aviation, such deviations can quickly turn routine operations into a catastrophe. Lean organizations understand this principle deeply. Standard work exists not to restrict people, but to protect them. It ensures that critical steps are followed every time, preventing variation that can lead to defects, injuries, or worse. This episode explores how aviation and Lean thinking share the same core truth: Standards are written from experience, and ignoring them removes the safeguards that keep systems safe. Whether in manufacturing, healthcare, aviation, or leadership, the lesson is clear—discipline in following standard work is what makes improvement possible and prevents tragedy.

    34 dk.

  2. 15 MAR

    The CFO vs. Lean: The Fight That Gets Lean Leaders Fired

    Mark DeLuzio, the Father of Lean Accounting, tells his experience and observations on how traditional cost accounting will derail a Lean Transformation. In many organizations, Lean transformations don't fail on the shop floor—they fail in the finance office. In this episode, "The CFO vs. Lean: The Fight That Gets Lean Leaders Fired," we examine a pattern that plays out in companies across industries: Lean improvements begin to transform operations, but traditional cost accounting systems tell leadership the exact opposite story. As inventory falls, batch sizes shrink, and flow improves, the accounting system often reports declining "efficiency," higher unit costs, or unfavorable absorption variances. The numbers appear to signal failure—even when operational performance is clearly improving. When executives rely on these metrics, the Lean initiative becomes the scapegoat. Too often, the Lean leader is blamed for results that are actually caused by outdated financial measurement systems. In this episode, we unpack the structural conflict between Lean principles and traditional cost accounting, explore why CFOs frequently defend these legacy systems, and explain how perfectly "correct" financial reports can lead companies to make deeply wrong decisions. Most importantly, we discuss how organizations can realign finance with Lean thinking so the transformation—and the people leading it—don't become casualties of the numbers.

    38 dk.

  3. 1 MAR

    The Illusion of Business Logic: Brilliant at Home, Illogical at Work

    In this episode, you'll be able to take away why many "logical" workplace measures and incentives can drive behavior that conflicts with Lean principles, and why comparing work decisions to everyday home-life decisions can make Lean concepts easier to understand and teach. You will hear about various examples, including grocery shopping and volume discounts, which highlight purchase price variance and excess inventory. You will explore the concepts of push versus pull using the supermarket and kanban approach. You'll gain insights into utilization and overall equipment effectiveness (OEE) and understand how "banking" uptime can lead to overproduction and unmet demand. Additionally, you will investigate changeover strategies using a multi-part thermoforming case, illustrated through a barbecue analogy comparing hot dogs and hamburgers. Finally, you will discover why oil leaks and poor visual management are perceived differently in the workplace compared to a car context, including the use of dashboards, warning lights, signs, and scoreboards. Timestamps: 01:31 Lean Accounting Origins 04:20 Buying in Bulk Trap 06:31 Pull Systems Grocery Lesson 08:05 Utilization Incentives Myth 11:27 Absorption Accounting Reality 12:44 Changeover Barbecue Analogy 17:52 SMED Rethink Changeovers 18:40 Fix Leaks Like Cars 21:38 Visual Management Everywhere 25:16 Bring Lean Home and Work

    29 dk.

  4. 15 ŞUB

    Book Review - Accidentally Aligned with Jason Neal

    A shop floor comment stops everyone in their tracks: the work finally matches what the customer actually needs. That is the spark behind Accidentally Aligned, and it opens a bigger issue most leaders dodge: alignment does not come from posters, audits, or a new playbook. It comes from how leaders behave when the process is broken, and the numbers are ugly. Mark and today's guest, Jason Neal, get into the messy middle of transformation: earning trust at the Gemba, protecting dignity when tempers flare, and dealing with the damage caused by "Lean policing." They also tackle a practical trap that shows up everywhere: leaders say they want engagement, then they take away overtime without replacing it with a better system. The result is predictable. So is the fix. If you are trying to keep momentum after the first wave of kaizen, this episode gives you language and moves you can use on Monday morning. Timestamps: 00:06:48 - Accidentally aligned with the customer voice 00:10:24 - Respect for people when the process fails 00:22:38 - Trust as the foundation for Lean sustainment 00:22:51 - When the Lean office becomes an audit function 00:23:37 - Losing credibility by switching to policing behavior 00:25:33 - Stopping disrespect before it becomes normal 00:34:54 - Turning overtime into kaizen time without breaking trust 00:35:12 - Why cutting overtime first backfires

    45 dk.

  5. 1 ŞUB

    Are You Set Up to Win? - Find Out Here!

    Most Lean efforts do not stall because people hate improvement. They stall because the system was never built to support it. This episode gives you a fast, practical lens for evaluating whether your organization is built to sustain improvement. You will learn how to recognize common traps that keep Lean efforts stuck, why certain measurement habits create the wrong behavior, and how to distinguish capability building from project theater. By the end, you will have a sharper way to assess your structure, roles, support functions, and operating rhythm, so you can stop guessing and start fixing what is really holding you back. Timestamp highlights 00:02:03 - Calling Lean a "program" is a red flag 00:05:09 - Under-resourced Lean office becomes admin, not a capability builder 00:08:43 - Lean leaders too low in the org cannot move mountains 00:09:55 - Combining Lean with a line role guarantees Lean loses 00:12:03 - Lean office should develop problem solvers, not rack up project points 00:18:36 - Lean audits signal inexperience and tool worship 00:22:54 - One standard problem-solving method beats a mix of A3 8D and random playbooks 00:28:32 - Hino Motors got nine implemented suggestions per person per month by building in time and support 00:32:14 - Value streams in name only when functions still control decisions and measures

    46 dk.

  6. 15 OCA

    Stop Misusing the 2-Bin Kanban System

    Mark DeLuzio discusses how the 2-Bin Kanban is meant to ensure the operator does not run out of parts.  Find out why it should not be used to structure your primary Kanban system.

    16 dk.

  7. 8 OCA

    Let's Make 2026 a Year of "Return to the Basics"

    Mark DeLuzio discusses the confusion that exists in the Lean Community, and the Lean Consulting industry and academia are primarily to blame. Returning to Lean Basics and ignoring distractions like Kata, Gemba Walks, Lean certifications, and other consulting “innovations,” which are designed to sell books and consulting services.

    42 dk.

  8. 15.12.2025

    Where Are The Engineers?

    Mark DeLuzio discusses the absence of engineers from the Gemba in both manufacturing and design. He also discusses the sin of engineering, which he calls "Catalogue Engineers."

    20 dk.
Tümünü Görün (80)

Hakkında

The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.

Bilgi

  • Yaratıcı
    Mark DeLuzio
  • Aktif Yıllar
    2023 - 2026
  • Bölümler
    80
  • Sınıflandırma
    Uygun
  • Telif Hakkı
    © 2023-2025 Mark DeLuzio
  • Şovun Web Sitesi
    Lean 911

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