Gemba Academy Podcast: Lean Six Sigma | Toyota Kata | Productivity | Leadership

This week's guest is Hezi Korn. Ron and Hezi discussed TOC and how to identify and evaluate your constraints before automating anything. They also touched on some other important lean tools. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quote Hezi likes (2:16)

Hezi's background (5:35)

An Dr. Eliyahu M. Goldratt story (7:41)

Identifying and elevating constraints (11:48)

What Hezi would do if the market is the constraint (21:02)

Why you don't want the constraint to move (31:19)

Taking a systematic point of view (41:07)

What other tools Hezi uses (41:52)

About Throughput Dollar Days (48:59)

Podcast Resources

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Hezi on LinkedIn

What Do You Think?

What is your take on Theory of Constraints?

This week's guest is Andy Switky. Ron and Andy discussed lean thinking versus design thinking, and what the two worlds could learn from each other. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quotes Andy likes (1:47)

Andy's background and what he's up to (3:27)

Getting started in engineering (5:52)

Lean and design thinking (7:14)

Incorporating manufacturability (11:56)

A memorable design experience (13:32)

What design thinkers can learn from lean thinkers (17:48)

Teaching lean and design in an academic environment (19:27)

Advice for incorporating both (22:26)

Podcast Resources

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Code Name Collective

Andy on LinkedIn

What Do You Think?

Do you have any experience incorporating lean and design?

This week's guest is David Tuttle. David is the head of Precision Machining Technology at Platt Technical High School, and he explained how the program works and how it can be life-changing for students. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quote that David likes (3:01)

David's background (3:26)

The program at Platt Tech (4:53)

Why there aren't more programs like it (11:12)

How the pandemic affected the program (13:15)

How workplace development is changing (16:58)

Advice for building lean into the curriculum (18:22)

David's plans for the future (19:45)

Podcast Resources

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Precision Machining Technology at Platt Technical High School

David on LinkedIn

What Do You Think?

How else could teaching lean and manufacturing principles in high school be beneficial?

This week's guests are Max Krug and Pavel Kuviarzin. Part Two of a recent episode, Max and Pavel discuss everything from root cause analysis and problem-solving, to sustaining success. They also stressed the importance of visual management. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quotes that inspire them (2:33)

Their backgrounds (3:30)

Real-life examples of root cause analysis and problem-solving (6:29)

Identifying the problem you're trying to solve (10:45)

Quantifying the problem (14:01)

The importance of visual management (18:32)

The benefits of control charts, Pareto, etc (24:10)

Sustaining success (27:21)

Advice for experienced practitioners (33:24)

Advice for new practitioners (42:41)

Podcast Resources

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Future State Engineering

Pavel on LinkedIn

Max on LinkedIn

What Do You Think?

What visual management tools do you use?

This week's guest is Shannan Vlieger. Ron and Shannan talked all about Douglas Dynamics and their management system, DDMS. Shannan explained the five levers of DDMS and why they're important. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

Shannan's favorite quote (4:25)

Her background (4:59)

Why DDMS is important (8:13)

The five levers of DDMS (10:27)

Building DDMS into practice (11:20)

Leading through participation, not proclamation (14:20)

Think and act like a coach (17:52)

The five things they're focused on (22:19)

Eliminating fear and comfort (27:12)

Building positive tension, not stress (30:33)

A review of all five levers (34:09)

Podcast Resources

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Shannan on LinkedIn

The Fearless Organization

Douglas Dynamics Presentation PDF

Douglas Dynamics Presentation Slides

Henderson Products Virtual Tour

What Do You Think?

Which lever speaks to you the most? Why?

This week's guest is Sarah Tilkens.  Sarah talked about her journey as a leader at GE and how she has embraced her true self in the process. Sarah also explained her interest in becoming a life coach. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quote Sarah likes (3:41)

Sarah's background (4:44)

Learning your way forward (11:58)

The successes Sarah has had (13:47)

Her journey of self-identity (17:19)

Problem-solving at GE (19:01)

How they use leader standard work (27:02)

Sarah's interest in becoming a life coach (29:55)

Advice for those who are doubting themselves (38:29)

Podcast Resources

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Sarah on LinkedIn

GA 275 | Leading vs. Serving with Sarah Tilkens

What Do You Think?

Have you ever seen a life coach? What was your experience like?

This week's guest is John Knotts, Senior Coach at Gemba Academy. Ron and John took a deep dive into process improvement versus project-based approaches, and why the two can and should coexist. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quote that inspires John (2:59)

John's background (4:39)

Process improvement environments versus project-based environments (7:14)

What it means to be the "JEEP" (14:29)

The different leadership approaches (18:50)

Why Ron hates the "Control" aspect of DMAIC (21:28)

The cultural differences in perspective (25:39)

Tips for those going through certification (27:53)

Tips for those in process management (30:39)

Podcast Resources

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John on LinkedIn

GA 392 | Using Lean on a Horse Farm with John Knotts

What Do You Think?

In your experience, what are the pros and cons of process-based versus project-based approaches to continuous improvement?

This week's guest is Gemba Academy Co-Founder Ron Pereira. As we kick off the new year, Ron decided to share some of the observations he's made and the lessons he's learned recently, and how he's going to live and lead in 2022. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

Identifying your "Why?" (3:25)

Controlling what you can control (6:37)

Being aware of your confirmation bias (11:03)

The importance of developing good habits (17:04)

Being intentional (20:07)

The importance of having a support group (23:59)

Choosing your communication carefully (28:23)

Podcast Resources

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Episode 261 | Building the Habit of Excellence with James Clear

Ron on LinkedIn

What Do You Think?

What are you going to focus on in 2022?

This week's guests are Max Krug and Pavel Kuviarzin. Max and Pavel gave us their take on the relationship between lean, processes, and The Theory of Constraints. They also touched on the dangers of falling too far into one particular CI "camp." An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quote that inspires Max and Pavel (3:28)

Max's background (3:59)

Pavel's background (5:14)

What TOC is all about (8:17)

An example of using TOC (10:38)

Using Gantt charts (13:54)

Why the final editing is the constraint (21:57)

About "drum buffer rope" (24:23)

How they identify the root cause (27:52)

The dangers of CI "camps" (31:01)

Podcast Resources

Right Click to Download this Podcast as an MP3

Pavel on LinkedIn

Max on LinkedIn

Future State Engineering

The Goal

What Do You Think?

What has your experience been with TOC?

This week's guest is James Newell. Ron and James talked all about what VUCA means, how James introduced his team to lean, and more. An MP3 audio version of this episode is available for download here.

In this episode you'll learn: 

The quotes that inspire James (2:12)

James' background (3:30)

What VUCA stands for (5:58)

Practicing lean in a volatile setting (6:40)

The two kinds of leadership (18:20)

Why the environment was VUCA (18:51)

How extreme interviewing works (21:10)

Handling work counsels (24:10)

Learning the practical parts of lean (26:35)

How it's been going since James left (31:21)

Podcast Resources

Right Click to Download this Podcast as an MP3

James on LinkedIn

GA 322 | Tailoring the Kata Model with James Newell

GA 224 | How to Apply Lean in Different Countries with James Newell

What Do You Think?

Have you ever been in a VUCA environment? Describe your experience.