Quality Time With MoreSteam

Dan Swartwout

On Quality Time with MoreSteam, a variety of guests will join host Dan Swartwout to discuss continuous improvement, operational excellence, and business-related issues. You can find new episodes of Quality Time with MoreSteam on moresteam.com.

  1. 5d ago

    Digital Twin For Continuous Improvement With Michael Schank

    On this episode of Quality Time with MoreSteam, author and entrepreneur Michael Schank joins the show. Michael spent 13 years at Accenture and 10 years at EY before leading Process Excellence for the US Consumer Bank at Citibank. In that role, he had responsibility over elements of process mapping, business process improvement, and a specific Lean team. Later, Michael wrote the book Digital Transformation Success. He is also the founder and CEO of Insight Twin, a company that leverages AI to build a digital twin of an entire organization. After revealing a startling statistic about the success of transformation projects, Michael breaks down his Process Inventory framework with host Dan Swartwout. Process Inventory is the list of things that people actually do. From there, Michael discusses the concept of "digital twin," which is a new topic for Quality Time with MoreSteam. A digital twin of an organization is a virtual replica of everything an organization actually does. Put those two ideas together, and transformation leaders know exactly who owns what. Everyone from the Lean team to IT to risk management works off the exact same picture of the business. Why is that important? Did you hear about the medical device company that paid consultants $92 million for an ERP overhaul that resulted in the company losing $2 billion in market value? If you haven't, Michael's got the details. This episode explores how Process Inventory and digital twin connect to the tools you already use, like fishbone diagrams, the five whys, and DMAIC. As a Process Excellence veteran, Michael understands continuous improvement. He also understands leadership, storytelling, and what it takes for continuous improvement to… well… continuously improve! As always, because this is Quality Time with MoreSteam, there are fun detours into 80's teen comedies, Three's Company episodes, and the optimum laughs-per-minute in a standup comedy set. We're talking about digital twin! So double your pleasure, double your fun, and download this episode to learn how a shared language around process can save your next transformation project from becoming the cautionary tale on a future podcast.   In this episode, you will hear about: 1:22 - Michael's background in consulting, banking, and process excellence 2:40 - 70% of transformation projects fail to meet their goals 4:17 - What a Process Inventory actually is 7:45 - Vertical alignment versus horizontal alignment 9:37 - What a digital twin is and where the concept came from 12:20 - The $92 million ERP disaster that cost a company $2 billion in market value 15:30 - How digital twin relates to process modeling 17:56 - Building trust with employees during a Process Inventory interview 19:02 - Digital twins in different industries, like banks and hospitals 23:02 - Michael's time as Head of Process Excellence at Citibank 29:04 - Writing Digital Transformation Success 35:08 - How Michael discovered Process Inventory 38:24 - Keeping Lean, risk, and technology teams on the same page 39:18 - What causes continuous improvement programs to stall 41:52 - Insight Twin and AI 46:39 - Laughs per minute   Additional Resources: Michael Schank on LinkedIn Insight Twin Michael's book "Digital Transformation Success" The Insight Twin Playbook MoreSteam's Introduction to Process Modeling Webinar QTWM: Simulating Success with Dr. Lars Maaseidvaag QTWM: Solving Healthcare Bottlenecks with Process Modeling MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn   Subscribe to Quality Time With MoreSteam: Apple Podcasts Spotify Amazon Music YouTube

  2. Sep 29

    James Hancock on Trust, Leadership, and Continuous Improvement

    On this episode of Quality Time with MoreSteam, James Hancock joins the show to talk continuous improvement, leadership, and what it really takes to earn trust on the plant floor. James leads operational excellence across North America for Greif. He's a math-loving Lean Six Sigma Black Belt who knows the tools and metrics, but he also understands that data alone doesn't always change people's minds. Effective improvement work requires listening, understanding the situation, and earning the trust of the people doing the work. That idea runs throughout James's conversation with host Dan Swartwout. They discuss why continuous improvement leaders can't walk into a situation assuming they already understand what's going on, how an engineering background can shape problem-solving, and why learning to meet people where they are matters just as much as knowing which tool to use. James shares some of the projects and experiences that shaped his approach, including the Black Belt project which still influences how he solves problems today; an award-winning improvement project at Printpack; and the use of a Plinko board to help an A3 project click. A3 Reports are designed to condense critical project information into a clear, visual format that supports problem-solving and decision-making. The conversation also gets into a persistent challenge in manufacturing: institutional knowledge. James talks about recognizing the health of a culture, the difference between coaching and training, and how his leadership approach has changed as his responsibilities have grown. And for something genuinely different, James is both an Eagle Scout and a third-degree black belt in karate. Yes, he's a Black Belt with a black belt! There's a direct line between what James learned through martial arts and Scouting and the discipline required to lead people through change at work. Whether you're practicing karate or developing continuous improvement capability, you have to put in the reps, be prepared, and prove yourself before earning the trust needed to lead others. That focus on capability and culture also shows up in Greif's broader Lean Six Sigma program. The organization has worked to build a global community of problem-solvers by combining training with real project work, coaching, recognition, and continued Black Belt development. Listen to this episode of Quality Time with MoreSteam to hear James's perspective on statistics, leadership, culture, and why successful continuous improvement depends on people as much as processes.   In this episode, you will hear about: 0:28 - James's takeaways from BP4OpX 2:12 - James's background and path to Greif 4:48 - The Lean Six Sigma Black Belt project that shaped how James still solves problems 7:12 - Using a Plinko board to make an A3 project click 9:03 - The innovation award project at Print Pack and lessons on measuring success 12:11 - How an engineering background shapes CI leadership 15:14 - What the MBOE program at Ohio State taught James about people 18:48 - The Kobe Bryant problem and meeting people where they are 20:30 - The difference between a coach and a trainer 24:24 - How karate and getting reps apply to continuous improvement 27:04 - Being an Eagle Scout and leading with be prepared 29:47 - The recurring challenge of institutional knowledge in manufacturing 34:56 - Reading the health of a culture on day one 38:05 - Adjusting leadership instincts as responsibilities grow 40:14 - Advice for anyone considering a black belt or the MBOE program 43:51 - What still excites James about CI work after all these years 46:21 - Just win, baby   Additional Resources: James Hancock on LinkedIn MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam on LinkedIn Dan Swartwout on LinkedIn Why Lean Six Sigma Projects Matter   Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  3. Sep 15

    Six Sigma Pioneer Mike Carnell on Leadership, Data, and AI

    Lean Six Sigma pioneer Mike Carnell joins this episode of Quality Time with MoreSteam. One of the most respected and longest-tenured continuous improvement practitioners, Mike shares the moment that set his path. After the Marine Corps, he started at Motorola, where he saw a problem that had lingered for 19 years get fixed in three days. At that moment, Mike decided that he wanted to be the problem solver. Since then, Mike's resume includes deployments in over 40 countries and direct working relationships with legendary CEOs such as Jack Welch. From that extraordinary career, Mike says he learned something simpler and harder to fake than any leadership technique or management trend: integrity, the most important characteristic of good leadership. Mike has some memorable stories from his decades in continuous improvement. In addition to leadership stories from Jack Welch, he shares the story of a platinum smelter in South Africa that everyone warned him not to touch because it might explode. Of course, that's the problem Mike wanted to solve. He spent four months sorting through data and figured out the solution involved turning one valve. That simple fix to a potentially explosive problem generated $100,000 in benefits during a worldwide platinum shortage. If you want to hear more from Mike, an earlier in-depth interview with MoreSteam CEO Bill Hathaway captures his experiences during the early development of Six Sigma at Motorola. He also explains how the methodology evolved, spread to other organizations, and eventually incorporated Lean thinking. Read the interview and explore the history of Lean Six Sigma. Mike and host Dan Swartwout also discuss AI in continuous improvement. Drawing from a recent presentation he gave to the ASQ Buffalo Section, Mike shares a statistic that should make any quality professional think twice: a leading AI tool was running at just 86% accuracy. That's a 14% error rate, nowhere near six sigma. Mike's take is simple. Read the output, but check the numbers and don't trust AI without independent verification. Even though Mike embraces the math behind Lean Six Sigma, he can still read a room. Listen to this episode and you'll be better at both. In this episode, you will hear about: 0:24 - Mike's introduction to Lean Six Sigma 3:08 - Mike's introduction to MoreSteam 4:04 - Continuous improvement deployments across the world 9:44 - How Mike works with leaders 10:53 - Working with Jack Welch 17:13 - The common trait of successful leaders 18:10 - Lessons learned from Mike's time in the Marines 20:09 - Mike's thoughts on "quick wins" 20:47 - Fixing the unfixable smelter 25:06 - Mike's AI presentation to ASQ Buffalo 27:07 - Verifying the accuracy of AI output 30:23 - Standup comedy and continuous improvement 31:19 - Being able to read the room 34:00 - The need for rigorous statistical analysis 38:47 - MoreSteam and Mike   Additional Resources: Mike Carnell on LinkedIn Carnell Holdings Mike Carnell AMA on Reddit MoreSteam's Website MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam on LinkedIn Dan Swartwout on LinkedIn Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  4. Sep 1

    Visual Management and Lean Culture with Joel Hugghins

    On this episode of Quality Time with MoreSteam, Joel Hugghins joins the show. Joel got his mechanical engineering degree at MIT. Since then, he has spent thirty years leading Lean transformations across industries as diverse as HVAC manufacturing and oil and gas. Today, Joel represents AME on the Lean Certification Alliance board, alongside representatives from the Society of Manufacturing Engineers and the Shingo Institute. Few practitioners can speak to Lean at such a high level across so many industries. Joel and host Dan Swartwout talk about taking Lean somewhere unexpected. Like a mud plant. (If you don't know what a mud plant is, don't worry. Dan didn't either.) Joel spent years in oil and gas working on the fluids that get pumped down a well. The oil-and-gas industry was built on batch thinking. But Joel helped make the shift to single-piece flow. Then there are the Legos. Early in his career, Joel needed to lay out an 80,000 square foot plant. He skipped the drafters. He skipped the model makers. Instead, he went to the store and bought $250 worth of Legos. Joel built the entire plant to scale. As a result, what used to take three weeks took just two days. Joel also shares his take on a ninth waste. He calls it misalignment. Imagine a rowing crew. One person out of sync slows down the entire boat. Maybe you're interested in hearing from one of the most acclaimed Lean practitioners in the game. Or maybe you're a Gen X'er who has nostalgia for the "Zach the Lego Maniac" commercials. Either way, this episode is for you. In this episode, you will hear about: 0:23 - Joel's background 1:11 - Lean Six Sigma and mechanical engineering 3:11 - Process improvement in the oil-and-gas industry 4:08 - Lean Six Sigma in liquid mud plant design 7:33 - The Ninth Waste: misalignment 10:22 - Joel's association with AME 12:38 - Creating alignment on your team 14:29 - Engagement and respect for people 17:40 - Overall equipment effectiveness (OEE) 21:01 - OEE outside of traditional manufacturing settings 24:58 - Joel returns to train in an operational excellence leadership role 29:03 - Changing the culture of an organization 30:36 - Effective communication with leadership about changing the culture 33:43 - Visualization as the most important tool 37:43 - The Lego story! 41:36 - Project scoping for smaller organizations 44:21 - Positive feedback after solving problems 46:43 - Congratulations Joel!   Additional Resources: Joel Hugghins on LinkedIn Hugghins Performance Consulting MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn    Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  5. Aug 18

    Leadership Culture and Organizational Change with Jason Barger

    Jason Barger, leadership consultant and author of Thermostat Cultures, has a theory about why an improvement effort can start strong and then fade a few months later. It's the difference between a thermometer and a thermostat. You might be thinking, "I don't get it." But after this episode of Quality Time with MoreSteam, you definitely will. Jason is also a keynote speaker, the author of three other books and the host of The Thermostat Podcast. As Jason had previously noted, "The most compelling leaders, teams, organizations, families or collection of humans of any kind operate in thermostat mode. They calibrate their mind and heart to set the temperature for the vision and culture they want to create." Jason describes what separates reactive teams from proactive ones. He breaks down his six A's for leading change and explains why rest matters as much as "grind" or "hustle" for truly elite performance. It's all here. Servant leadership. Organizational alignment. And what you learn from spending an entire week in airports. (Yes, you read that last part correctly.) For Lean Six Sigma and operational excellence professionals, this episode offers a new perspective on some familiar themes. You can't have lasting change without a culture that supports it. Listen and learn how leaders can set the temperature instead of just reacting to the heat.   In this episode, you will hear about: 1:09 - Meet Jason 3:15 - Step Back From the Baggage Claim 7:09 - The six leadership mindsets: clarity, inclusivity, agility, grit, rest, and ownership 10:01 - Why rest is such an important mindset 13:14 - Making leaders understand the importance of rest 15:09 - Organizational alignment and aspirational thinking 18:39 - Thermostat cultures 22:24 - How thermostat cultures help organizations sustain change 26:18 - Capital L leadership versus lowercase L leadership 28:31 - Investigating cultural dissonance 32:01 - Jason's proactive culture case study 35:32 - Being a servant leader 38:24 - Inauthentic leadership 41:13 - Balancing hard data with the emotional and cultural side of change 44:35 - Something leaders can start doing right now 47:17 - What's next for Jason?   Additional Resources: Jason Barger's Website The Thermostat Podcast Jason Barger on LinkedIn Jason Barger's Books on Amazon Jason Barger on YouTube MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn    Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  6. Aug 4

    Kaizen Event Facilitation and Sustainability with Adam Lawrence

    On this episode of Quality Time with MoreSteam, the Kaizen Ninja Adam Lawrence joins the show. Adam is a recognized continuous improvement leader and Lean transformation coach who created The Wheel of Sustainability. Because he has led hundreds of Kaizen events, Adam has seen what happens when a team fixes a problem in a week. But he has also seen what happens when that fix slowly fades away. Adam and host Dan Swartwout talk about what really happens during a Kaizen event. As a facilitator, Adam works to make a team believe, "We did this," instead of, "Somebody else told us what to do." That is the ninja part. Just like a ninja disappears, the team senses no trace of Adam in resolving the problem. Adam shares the wins, the losses, and even the times where he kept quiet so the team could discover a solution for themselves. You will also learn how improv, humor, and a few bold questions can turn a scary change into something people celebrate. And what about The Wheel of Sustainability? It takes leadership commitment at the center and eight spokes shooting out from the hub. Those spokes include clear benefits, accountability, and recognition. Think of it as the flux capacitor of continuous improvement. This episode is for the Columbo in all of us. Are you stopping at "4 Whys"? Learn why you need to ask "just one more question."   In this episode, you will hear about: 0:19 – What is a Kaizen event? 1:39 – Being a Kaizen Ninja 5:45 – Lessons from facilitating over 400 Kaizen events 7:36 – Letting the team discover the solution 16:10 – The mindset of a successful Kaizen facilitator 21:16 – Dealing with a Kaizen event that nearly goes off the rails 25:30 – Common mistakes in running Kaizen events 28:53 – The difference between a facilitator and a coach 32:11 – Introducing improv into Kaizen 37:55 – Dealing with potential bad actors during a Kaizen event 41:16 – Observing team members during a Kaizen event 46:59 – The Wheel of Sustainability: sustainable change 56:25 – Don't be afraid to give Kaizen a go   Additional Resources: Adam Lawrence on LinkedIn Process Improvement Partners Process Improvements Partners on LinkedIn The Wheel of Sustainability on Amazon Sustainability System Assessment MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn    Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  7. Jul 21

    Lean Six Sigma Black Belt Insights with Kevin Yania

    On this episode of Quality Time with MoreSteam, Kevin Yania joins the show. Kevin is a Lean Six Sigma Black Belt and the Senior Manager of Process Agility at Bread Financial. It started like this for Kevin. Years ago, he got an email. The signature said, "Black Belt." Kevin was confused because he thought it was about karate. Yes, Kevin honestly believed his co-worker's email signature included martial arts credentials. But that mix-up turned into a real career. Kevin earned his Green Belt, then his Black Belt, and now he's coaching the next generation of continuous improvement practitioners. Kevin and host Dan Swartwout have a conversation about actually doing the work of continuous improvement. What makes people believe in the data being presented? Because being right and being believed are not always the same thing. They talk about trust and readiness for change. They explore stakeholder and organizational alignment. Kevin also explains why operational excellence needs to be a part of everyday work. It can't just be a project that ends with a high five and a balloon. It's about sustaining change, which might be the hardest part of the job. Finally, you might wonder why Kevin is such a polished guest. It's because Kevin used to co-host his own podcast. It was called The Ohio Beer Cast. Yes, that was a real thing. Process improvement, karate confusion, and beer. Because it's Quality Time with MoreSteam, somehow it all fits. In this episode, you will hear about: 0:50 - Meet Kevin 2:20 - Black Belt training through MoreSteam 3:24 - Putting Lean Six Sigma concepts into practice 4:35 - Telling a story with data 7:51 - The day-to-day work of a Lean Six Sigma Black Belt 9:18 - Coaching new continuous improvement practitioners 11:04 - Stakeholder alignment 11:56 - Unexpected takeaways from project work 13:55 - Lean Six Sigma and change management 16:19 - Resistance to change 18:10 - The Center for Operational Excellence at The Ohio State University 19:23 - Common mistakes in operational excellence 21:53 - Kevin's old podcast: The Ohio Beer Cast 23:48 - Advice for people going through Black Belt training 26:03 - What Kevin would change about how organizations approach continuous improvement   Additional Resources: Kevin Yania on LinkedIn MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn    Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

  8. Jul 7

    Stakeholder Analysis And The Art Of Listening With Melissa Sherman

    On this episode of Quality Time with MoreSteam, Melissa Sherman joins the show. Melissa is vice chair of the Michigan Lean Consortium. She is also an industrial engineer, longtime Lean practitioner, teacher, and consultant. Melissa spent years with utility companies before moving into consulting work that often brings Lean together with ISO standards. As you'll hear, she has the ability to make continuous improvement feel practical and human. Melissa and host Dan Swartwout talk about what it looks like to lead improvement in a regulated environment like utilities. They also discuss tips for winning over naysayers and why curiosity and listening beat a complicated toolkit every time. But there is one tool that Melissa consistently uses. That's stakeholder analysis. Melissa explains why stakeholder analysis is so important and, perhaps more importantly, how to actually conduct one. As a teacher and coach, Melissa uses everyday examples like loading a dishwasher or maintaining a car to help people see Lean ideas in their own lives. And because a change that doesn't stick isn't really a change, Melissa stresses the importance of setting calendar reminders and checking in with the team. Of course, the conversation with Melissa is informative. But Dan really appreciates how Melissa shares expert advice with so much positivity. Also, you may never hear a podcast episode that applies so many Lean principles to standup comedy. An expert Lean practitioner, positivity, and standup comedy? That sounds like the right pull system for a great podcast.   In this episode, you will hear about: 0:23 - The Michigan Lean Consortium 3:43 - From Industrial Engineer to Lean Practitioner 4:55 - Continuous Improvement work in the utilities space 6:58 - Lean principles and ISO standards 8:32 - Melissa first step in a new improvement effort 10:27 - Dealing with people when the technical fix looks solid 15:02 - The importance of Stakeholder Analysis 16:19 - Conducting a Stakeholder Analysis 19:46 - Making change stick when the project is over 23:04 - Watching people see how Lean ideas connect to what they actually do 27:45 - Creating and empowering problem solvers 31:15 - Winning over naysayers 35:18 - How Lean is evolving 38:42 - Using everyday examples to teach Lean concepts 42:52 - Practical tips for leading improvement or change work 45:12 - What's next for the Michigan Lean Consortium   Additional Resources: Melissa Sherman on LinkedIn The Michigan Lean Consortium Melissa's bio on the Michigan Lean Consortium website MoreSteam's YouTube Channel Quality Time With MoreSteam on Facebook Quality Time With MoreSteam on Instagram Quality Time With MoreSteam on LinkedIn MoreSteam's Website Subscribe to MoreSteam's Newsletter MoreSteam on LinkedIn Dan Swartwout on LinkedIn    Subscribe to Quality Time With MoreSteam Apple Podcasts Spotify Amazon Music YouTube

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On Quality Time with MoreSteam, a variety of guests will join host Dan Swartwout to discuss continuous improvement, operational excellence, and business-related issues. You can find new episodes of Quality Time with MoreSteam on moresteam.com.

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