Only a few weeks into taking over Sperrin Metal, Ryan Tierney is revealing the first real progress inside one of the most chaotic factories he has ever stepped into in this podcast recorded live at the Gemba Summit.This is the story of what he found on day one, what has changed already, and how Lean Thinking is beginning to transform a 63-year-old manufacturing company from the inside out.In this first-phase update, Ryan shares the breakthroughs, the challenges, and the mindset shifts that accelerated improvement faster than anyone expected.From disorganised processes to early wins, from scattered workflows to the foundations of daily improvement, this episode shows the real-world reality of starting Lean in a place that desperately needed it.You’ll see:🟢 What Ryan discovered when he first walked into Sperrin Metal🟢 How the team responded to Lean from day one🟢 The first systems put in place to stabilise workflow🟢 Why culture and structure came before tools🟢 How the Lean Dream Team unlocked early momentum🟢 The mindset shifts that allowed progress in weeks, not months🟢 Why chaos is the best starting point for transformationIf you’re a factory manager, operations leader, or Lean practitioner, this update gives you a rare inside look at what Lean actually looks like in the early days — messy, fast, energising, and full of opportunity.Watch now and see how Lean Made Simple is beginning to reshape Sperrin Metal from the ground up.⸻🔗 Next steps➡️ View the keynotes from the Gemba Summit at the ⁨@GembaDocs⁩ YouTube channel➡️ Order the book Lean Made Simple – 12 Proven Steps for Creating a Vibrant Lean Culture: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour➡️ Join the Lean Made Simple community: https://www.leanmadesimple.com/community⸻✅ KeywordsLean manufacturing Lean transformation continuous improvement factory update factory tour Kaizen 5S workflow improvement operational excellence manufacturing systems Lean culture Lean leadership Sperrin Metal transformation Lean Made Simple Gemba Summit production efficiency#LeanManufacturing #ContinuousImprovement #LeanTransformation #SperrinMetal #LeanMadeSimple #OperationalExcellence #Kaizen #ManufacturingTransformation #LeanLeadership #LeanCulture

Ryan Tierney (Lean Made Simple) delves deep into Ireland's BIGGEST ever Lean summit, Gemba Summit at Titanic Belfast, Northern Ireland on 20th-21st October 2025.Find out more about Gemba Summit and:- Whit can be your next lean TURNING POINT- Why people are travelling from all over the world to EXPERIENCE lean- HOW you can join some of the world top lean leaders➡️ Book your GEMBA SUMMIT tickets today: https://gembasummit.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour➡️ Subscribe to the Lean Made Simple podcast.Apple Podcasts: https://podcasts.apple.com/gb/podcast/lean-made-simple-transform-your-business-life-one-step/id1693831884Spotify: https://open.spotify.com/show/6bUJ0QwamrZjjvfpUkQrCq

Ryan Tierney (Lean Made Simple) sits down with podcast host Matthew Thompson to get deep into why he has made the boldest move of his life and made a high stake move that will be the ultimate test of lean.🟢 Ryan Tierney leaves his successful business to take on his biggest Lean challenge yet.🟢 Why Sperrin Metal needs more than just tools — it needed a complete culture reset.🟢 Discover the real-world pressures behind buying a struggling factory and leading from the front.🟢 This episode explores what it means to truly believe in Lean — when the stakes are high and nothing is guaranteed.🟢 A personal story of purpose, risk, Draperstown pride, and building something that lasts.➡️ Find out more about Sperrin Metal at www.sperrin-metal.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with Aiden Rogers from Rolls Royce, one of the world's most prestigious brands to dig deep into how they do lean.✅ Aiden Rogers shares how Rolls-Royce shifted from tool-driven fixes to culture-led continuous improvement.✅ Learn how a 100-year family legacy at Rolls-Royce shaped Aiden’s leadership vision.✅ Discover the power of “fix what bugs you” as a culture-builder, not just a process tool.✅ Real-world Lean examples — from silicon cases to digital tracking — making massive impact on the shop floor.✅ A behind-the-scenes look at how Toyota’s influence and humility are driving meaningful change inside one of the world’s most prestigious brands.⸻➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with lean officials Phil Catherwood (Welsh Government), Robert Hernan (Enterprise Ireland) and John McClune (Invest Northern Ireland) to talk what it takes to bring lean to the nations.

🌍 Three national leaders share how Ireland, Wales, and Northern Ireland are driving lean transformation at scale.

🌍 Why site visits, clusters, and exemplars are more powerful than PowerPoints — and how they’re used to spread Lean thinking.

🌍 A behind-the-scenes look at how national Lean programs are structured for SMEs, not just large corporations.

🌍 The real challenge? It’s not tools, it’s leadership — and helping everyday managers become confident Lean leaders.

🌍 A rare cross-border conversation on collaboration, culture, and how Lean is shaping the future of work.

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➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com

➡️ Welsh Government LEAN ASSISTANCE: https://www.gov.wales/huge-productivity-gains-toyota-assistance-programme

➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store

➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with Make UK mentor Mike Dimmack and lean apprentice Ruby Handley to discuss the future of lean in the UK and beyond.

✅ Meet Ruby, a passionate Lean apprentice reshaping how we think about manufacturing at just 20 years old.

✅ Discover how Make UK trains the next generation of engineers through hands-on Lean learning.

✅ Why common sense, not complexity, is the key to great Lean thinking.

✅ Hear why apprenticeship routes are gaining serious momentum — and why they’re more relevant than ever.

✅ Insightful reflections on legacy, motivation, and empowering young talent from an award-winning Make UK mentor.

➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com

➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store

➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with Toyota HR General Manager Liam Holmes to talk all things culture and people at the world's best manufacturer.

🔴 Discover how Toyota develops not just cars, but careers – from the production line to leadership.

🔴 Liam shares a 30-year journey of people-first principles and Lean culture.

🔴 Learn the structured training system that gets results and builds loyalty.

🔴 See why emotional intelligence matters just as much as engineering skill.

🔴 Find out how Toyota prepares for the future through apprenticeships and continuous improvement.

➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com

➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store

➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with former Premier League footballer Thomas Robson Kanu about his journey as an international soccer star turned SME owner and lean practitioner.

Premier League to Entrepreneur – Thomas shares how a career-threatening injury became the unlikely spark for a functional wellness brand.

Snapped Knee to Secret Weapon – Hear the story behind the homemade turmeric blend that changed his life and career.

Scaling from Kitchen to 15,000 Shots a Week – The journey of building a lean beverage business from scratch, without a blueprint.

Lean Thinking Meets Elite Mindset – How Thomas applies high-performance principles from football into continuous improvement and culture.

Taking on Industry Giants – Competing with global brands through purpose-driven products and smart processes.

➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com

➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store

➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with lean PhD Alisha Gibbons.Find out:- What its like being a woman in manufacturing- How can Toyota and others make lean cool- Attracting young people into lean for the future- Is lean really mean?➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour

In this episode of Lets Talk Lean, Ryan Tierney (Lean Made Simple) and Paul Blahyj (Toyota Lean Management Centre) sit down with Totota senior manager Simon Rowley.Find out:- the three behaviors that all Toyota employees much do- how many times do they stop the line each week?- what its like living lean beyond the workplace- how Toyota finds their next senior employees➡️ Work with TOYOTA LEAN MANAGEMENT CENTRE: https://tlmc.toyotauk.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour