WLEI - Lean Enterprise Institute’s Podcast

In this episode of the WLEI podcast, LEI's guests are Mary Nell Egan and Lisa Karam from MassMutual, a leading insurance company. Egan and Karam delve into the intricacies of transformation in a traditionally cautious, large organization.

In our discussion, we explore several key themes:

• MassMutual’s evolution from a tool-centric to a customer-value approach in their lean journey.

LEI chats with Frank Paluch, Retired President of Honda R&D Americas, and Lara Harrington, Retired Honda Chief Engineer. Frank and Lara share how Honda utilized Lean Product and Process Development principles to launch successful vehicles like the Honda Passport. 

During the conversation we dive into the following: 

• Understanding Customer Value – As Chief Engineer of the Honda Passport Lara explains how she used rapid prototyping and gathered consumer feedback early in the development process to determine a vehicle design that would appeal to customers and grow Honda’s market share.

Special note: Lara and Frank will lead a keynote about Lean Product and Process Development at the Lean Summit in March 2024. To learn more and register, click here.

In this episode of the WLEI Podcast, we speak with Jill Katic and Grace Eovaldi from Barton Malow, a major construction company that has recently seen significant growth. Jill and Grace share how they've been working to foster a culture of problem solving throughout Barton Malow, principally through a program dubbed Lean University. 

During the conversation we dive into the following:  

Lean Principles and A3 Problem-Solving: Exploring Lean University's five-day training program, which introduces participants to lean principles and the A3 problem-solving method over a three-month period. 

Problem Identification and Analysis: How Jill and Grace use the program to help participants identify and dissect problems in their work, guiding them in developing effective countermeasures. 

Business and Cultural Results at Barton Mallow: Insights into the tangible business outcomes and cultural shifts experienced by Barton Malow since beginning Lean University. 

Lean Thinking and Problem-Solving Skills: The significance of Lean University for organizations seeking to cultivate lean thinking and problem-solving abilities among their employees. 

Barton Mallow's Lean Journey: An overview of Barton Malow's experience with Lean University and its role in transforming the company's culture. 

Special note: Jill and Grace will lead a learning session about building a problem-solving culture through Lean University at the Lean Summit in March 2024. To learn more and register, click here.

In this episode of the WLEI Podcast, we talk with Fabrice Bernhard and Catherine Chabiron. Fabrice is the co-founder of Theodo, a fast-growing software company, and Catherine is the author of the new book, Learning to Scale at Theodo: Growing a Fast and Resilient Company.

Fabrice and Catherine share how Theodo has seamlessly integrated lean thinking into its management system enabling it to grow rapidly while maintaining a customer-first mindset and ship quality software.

During the conversation, we dive into:

• Lean vs. Agile: How Theodo found lean thinking and how it complements agile, while challenging traditional perspectives in the software industry.

• Quality vs. Speed: Navigating the delicate balance between producing high-quality code and meeting the demands for rapid delivery.

• Customer Focus: How lean has enhanced Theodo’s customer-centric approach, making it a hallmark of their operations.

• Learning Organizations: The role of continuous learning in building resilient teams that not only solve technical problems but contribute to organizational growth.

• People Development: How Theodo leverages problem-solving at the gemba to foster a culture of continuous improvement and employee development.

Special note: During the conversation, we mention the book The Toyota Way of Dantotsu Radical Quality Improvement, which Theodo has been using to transform its approach to improving quality.

In this episode of the WLEI Podcast, we speak with Mehmet Gur, Senior Director of Operations Engineering at DHL eCommerce. He has been leading the company's next-generation automation efforts. Since the pandemic, DHL eCommerce – DHL's business-to-consumer unit – has faced dramatic increases in volume. This surge required new automation technology to meet customer demand and heightened expectations regarding delivery speed. Mehmet oversees a large team of technical engineers tasked with meeting this challenge. 

During the discussion we touch on:  

• Lean Thinking and Automation: How Mehmet's team used value-stream mapping to close the gap between automation equipment’s theoretical throughput and actual throughput.  

Mehmet will lead a learning session on these themes at the LEI Lean Summit in March 2024. To learn more and take advantage of early registration discounts, visit lean.org/summit. Register by October 31 to save up to $900 on your summit registration. 

In this episode of the WLEI Podcast, we speak with Jay Multanen and Jared Ragozzine from Bestbath, a manufacturer specializing in showers and bathtubs for both commercial and residential buildings. Jay is the co-CEO, while Jared is Director of Lean and Continuous Improvement. 

During the conversation we touch on:  

Organizational Transformation: Gain insights into how Bestbath has built a problem-solving culture through methodical structural changes and targeted people development strategies. 

Competitive Differentiation: Understand how adopting lean practices has not only streamlined their operations but conferred a significant competitive edge in the market. 

Strengthening Partnerships: Learn how lean thinking has fortified Bestbath's relationships with their construction trade partners, thereby enhancing collaborative opportunities. 

Profit-Share Model: Explore Bestbath's innovative profit-sharing scheme that has been pivotal in fostering the right behaviors across all levels, from the C-suite to the shop floor. 

Jay and Jared will host a learning session on building a problem-solving culture at the Lean Summit on March 19-20, 2024.

Register by October 31 to save up to $900 on your registration. Click here to learn more and register.

In the latest episode of the WLEI podcast, we delve into hoshin kanri (strategy deployment) with Otto Funke and Joseph Tamayo from GlobalFoundries, a global leader in semiconductor manufacturing. Otto has overseen the strategic planning process at one of GlobalFoundries' production facilities for sixteen years. He will share insights on how the site has developed a robust process that has withstood leadership changes. Alongside Joseph, they will explore how this process creates alignment around objectives, both vertically and horizontally, enabling front-line workers to link their tasks to broader corporate goals. Furthermore, they will shed light on how this strategic approach is instrumental in cultivating GlobalFoundries' next generation of leaders.

Otto and Joseph will host a learning session on hoshin kanri at the Lean Summit on March 19-20 with optional workshops on March 21-22.

Register by October 31 to save up to $900 on your registration. Click here to learn more and register.

In the latest episode of the WLEI podcast, we explore the topic of organizational change with Dr. Lynn Kelley, former vice president of supply chain and continuous improvement at Union Pacific Railroad and author of the new book Change Questions.

Kelley posits that there is no such thing as a fixed plan for a successful transformation. Leaders must approach change situationally, recognizing they face unique challenges no single method could address. In her book, she proposes a series of questions that methodically guide management to implement change and measure its impact:

1. What is your value-driven purpose?

By grappling with these questions, leaders will be able to design and implement a lasting transformation that leads to better business outcomes and engaged employees.

To learn more about the book and download a free digital workbook, check out www.changequestions.net

In the latest episode of the WLEI podcast, we take a deep dive into a new venture whose goal is to rekindle America’s industrial tradition. Re:Build Manufacturing was founded by former Amazon executive Jeff Wilke in 2021. We sat down with its CEO Miles Arnone and Chief Lean officer Bonnie Davis to learn about Re:Build Manufacturing’s purpose and how it fulfills it.

For decades U.S. manufacturers swept up by the opportunity to maximize profits with low-cost labor have been offshoring manufacturing. But the short-term boost in profits has generated long-term, unintended consequences.

Communities that once thrived on manufacturing experienced severe economic downturns. This decline led to increased economic inequality, as those who lost their jobs struggled to find employment that matched their skills and offered comparable wages. Also, manufacturers struggled to protect their innovations as overseas suppliers threatened intellectual property theft or infringement. And the offshoring trend has eroded America's manufacturing and engineering capabilities. As companies began to rely on overseas suppliers, they lost valuable knowledge and skills that were once a hallmark of American industry.

During the podcast, Miles and Bonnie delve into the specifics of how Re:Build's strategy works, as well as the company's culture and mission. They provide valuable insights into the future of American manufacturing and the vital role that Re:Build aims to play in reshaping it.

While Lean can trace its direct roots to the production system launched by Toyota more than 50 years ago, its timeless appeal translates into immediate practical countermeasures in a surprising number of situations. What A Unicorn Knows, a terrific new book by authors Matt May and Pablo Dominguez, proves this by presenting a comprehensive application of lean principles that couldn’t be more timely. Join us for their conversation with WLEI host Tom Ehrenfeld for a wide-ranging exploration of the deep relevance of lean for growing companies today.