In this episode of Buy the Numbers, host Mike Payne sits down with continuous improvement coach and Lean Six Sigma Master Black Belt Brian Karp to dig into the metrics that matter most for manufacturing leaders. Together, they explore how data can be used not just to measure performance, but to transform culture, drive engagement, and spark meaningful improvement across every department.

For more than a decade, Brian has helped manufacturers simplify their approach to measurement—turning overwhelming spreadsheets and endless KPIs into tools that actually guide better decisions. He and Mike talk about where to start when you don’t have a dashboard, how to align KPIs with what customers truly care about, and how to avoid “analysis paralysis” when trying to improve processes.

Throughout the conversation, they uncover the real purpose of data collection: empowering teams to learn, not to punish. From establishing baseline metrics to tackling the “yeah, buts” that derail progress, Brian breaks down how to build a measurement mindset rooted in curiosity and continuous improvement.

Mike also shares firsthand how his own team at Hill Manufacturing worked with Brian to align their KPIs, trust their systems, and use imperfect data to make better business decisions. It’s a conversation that bridges the gap between engineering precision and human behavior—showing that the key to success isn’t just tracking numbers, but understanding the story behind them. 

You will want to hear this episode if you are interested in...

• (0:49) Brian Karp’s background in manufacturing and continuous improvement
• (2:00) How Mike met Brian through local grant programs and Lean training
• (3:12) The importance of connecting KPIs to business goals
• (4:03) Where to start when you have no KPIs—beginning with quality, delivery, and cost
• (6:13) Grow your top and bottom line with CliftonLarsonAllen (CLA)
• (8:25) Defining metrics that actually reveal performance problems
• (9:41) Keeping measurement simple—tracking exceptions instead of every instance
• (10:55) The myth of perfect data (and why “better” beats “perfect” every time)
• (12:20) Getting buy-in for change: why people resist and how to bring them along
• (19:32) Avoiding the “yeah, buts” that derail progress
• (20:32) Measuring even variable processes: everything can be counted
• (21:55) Check out SMW Autoblok’s catalog to leverage RASRAM
• (22:50) Drilling deeper into job costing and profitability analysis
• (24:19) Benchmarking data against real performance, not assumptions
• (28:31) The danger of changing definitions (consistency matters)
• (31:04) Bringing KPIs to the shop floor—making performance visible and celebrated
• (33:53) Manufacturers: Make sure your voice is heard
• (41:38) Using customer scorecards to define internal KPIs
• (43:58) Why continuous improvement never ends—and why that’s a good thing
• (47:46) Using benchmarking tools like Top Shops to gauge industry performance
• (49:00) How Hill Manufacturing has evolved its KPI culture over eight years
• (50:28) Hill’s next challenge: driving toward zero defects
• (54:08) Why you need to meet us at MTForecast

Resources & People Mentioned

• Grow your top and bottom line with CliftonLarsonAllen (CLA)
• Check out SMW Autoblok’s catalog to leverage RASRAM
• Why you need to meet us at MTForecast

Connect with Brian Karp

• CI Solutions 
• Connect on LinkedIn

Connect With Buy the Numbers

• Follow on LinkedIn
• Connect with Mike Payne on LinkedIn

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Audio Production and Show Notes by - PODCAST FAST TRACK