WLEI - Lean Enterprise Institute's Podcast

Connecting the Classroom to Industry: Experiential Lean Learning with Dennis Wade and Lisa Eshbach

In this episode of the WLEI podcast, we speak with Dennis Wade from Oakland University and Lisa Eshbach, PhD from Ferris State University. They share their universities' programs that provide hands-on lean learning experiences for students through collaboration with industry partners. 

In our discussion, we explore: 

• The backgrounds and roles of Dennis Wade and Lisa Eshbach in academia and their work connecting students to real-world lean projects. 
• The models used at Ferris State University and Oakland University for experiential learning projects, including course-based projects and paid internships. 
• The impact of these programs on students' development of lean skills and tools, as well as skills like collaboration and problem-solving. 
• Examples of projects undertaken by students, such as a kanban system for an eye clinic supply room and creating a food pickup process for a university food pantry. 

Dennis and Lisa will lead a learning session on connecting industry to academia at the Lean Summit on March 19-20 in Carlsbad, CA.

To contribute to the James P. Womack Scholarship, which funds student internships at Oakland University, email us at info@lean.org. Click here to read case studies from past student projects funded by the scholarship.

Extending Lean Thinking Beyond the Factory at MillerKnoll: a Conversation with Jennifer Trask and Brittney Heatherington

In this episode of the WLEI Podcast, our guests are Jennifer Trask and Brittney Heatherington from MillerKnoll. Trask is the Director of the MillerKnoll Performance System (HMPS) for business processes and dealer network, while Heatherington is a continuous improvement coach for the dealer network. 

In our discussion, we explore: 

• MillerKnoll’s methodical approach to people development. 
• How MillerKnoll has built a culture of operational excellence throughout its value stream from its factories to its dealers. 
• How MillerKnoll successfully engages dealers in problem-solving by coaching at the gemba.
• The importance of approaching problems situationally versus applying a fixed solution.

Defining Winning: Turning Around Operations Through Clarity and Ownership with Billy Taylor

In this episode of the WLEI podcast, LEI speaks with Billy Taylor, former operations executive at Goodyear Tire & Rubber Company. He is now President of LinkedXL and author of The Winning Link: a Proven Process to Define, Align, and Execute Strategy at Every Level. 

In our discussion, we explore:

• Billy’s career journey from third shift supervisor to director of North American operations for Goodyear.
• How Billy led a transformation of one of Goodyear’s worst-performing plants through instituting a few core principles: deliberate clarity, defined ownership, deliberate practice, and trust. 
• Billy’s approach to scaling a management system from a single plant to multiple plants across North America through intense collaboration with plant leaders. 
• The current challenges of retaining employees due to changing workforce mindsets post-COVID and how to re-engage workers.

Engaging Leadership in Lean at MassMutual

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.
• The methods Egan and Karam used to engage previously disengaged leaders with lean, linking continuous improvement to corporate strategy.
• The critical role of meeting people where they are in mitigating resistance to change.
• The significance of resilience in lean transformation.

Developing Products Customers Love: Discussing Lean Product and Process Development with Two Retired Honda Leaders

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.
• The Chief Engineer – Frank and Lara reflect on the chief engineer’s role, what makes a great chief engineer, and the matrix organization in which they work.
• People Development – Comparing hiring in engineering talent versus developing it internally.
• Future of the Auto Industry – Discussing the industry push toward EVs and contrasting Tesla’s approach to development to Toyota’s. 

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.

Building a Problem-Solving Culture: Insights from Barton Malow’s Lean University

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.

Exploring the Intersection of Lean and Agile: Lessons from Theodo

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.

Revolutionizing Logistics: DHL eCommerce’s Journey Applying Lean Thinking to Automation

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.  
• Automation Evaluation: What should organizations consider before investing millions in new technology. 
• People Development: How to use problem-solving at the gemba to not just solve intractable technical problems but develop engineers.  
• AI in Distribution: How emerging technologies are revolutionizing logistics for higher throughput and customer satisfaction. 

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. 

 

Transforming Corporate Culture: Bestbath’s Approach to Scaling Problem-Solving Capability

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.

Sustaining Strategy Deployment: Lessons from 16 Years of Practice at GlobalFoundries

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.