PODCAST · business
Lean 911
by Mark DeLuzio
The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.
Episodes
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Genba Ikigai – The 16 Habits of Lean Leadership with Mark Forkun
Why do Lean transformations fail—and what separates genuine transformation from “Lean theatre”? In this episode of Lean 911, Mark DeLuzio is joined by Mark Forkun, author of Genba Ikigai – Leading to Serve, for a practical discussion about Lean leadership, leadership habits, problem-solving,...
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Stop Copying Toyota’s Tools – Start Copying How Toyota Thinks
Why have so many organizations copied Toyota's tools, yet so few have replicated Toyota's success? In this episode of Lean911, we revisit Steven Spear and H. Kent Bowen's landmark article, Decoding the DNA of the Toyota Production System, and explore a fundamental lesson: TPS isn't primarily a...
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Lean at 8 Seconds – What NASCAR Pit Crews Can Teach Us About Lean
What can Lean leaders learn from a NASCAR pit crew, where three-tenths of a second can mean five car lengths and elite performance depends on five people executing as one? In this episode, we take the lessons from NASCAR’s pit road and translate them directly into Lean Operational Excellence. The...
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From Toyota to Danaher to Your Enterprise: Introducing Lean Horizons Academy
What if the Lean lessons that helped shape one of the world’s most respected business systems could be made available to everyone in your organization—anytime, anywhere, and in virtually any language? In this episode of Lean911, we introduce Lean Horizons Academy, a new approach to building...
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The Danaher Business System – 12 Things I’d Do Differently
When you build something that stands the test of time, it's tempting to believe you'd do it the same way all over again. But experience has a way of changing your perspective. In this episode, I look back at the creation of the Danaher Business System and share 12 things I would do differently if…
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Be The Magic: 4 Phases to Transform Your Life with Manish Chauhan
What if the biggest transformation in your life begins with a simple shift in perspective—not from believing life is happening to you, but realizing it is happening through you? In this episode, we explore Be The Magic: 4 Phases to Transform Your Life by Manish Chauhan, a practical and deeply...
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25th Anniversary Episode: Lean Horizons’ Reflections – The Rise of Lean Theater
As Lean Horizons celebrates its 25th anniversary, founder Mark DeLuzio reflects on a quarter century of transformation work across six continents and dozens of industries. In this special episode, Mark examines the evolution—and in some cases, the dilution—of Lean thinking since the early days of...
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How Hansei Builds Better Leaders
A CNC machine crashed on the shop floor. Nathan Corliss walked out as a young supervisor, angry and ready to blame the operator. What happened next became one of the most important leadership lessons of his career. Mark DeLuzio and Nathan talk about the moment that forced Nathan to confront his…
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Replay: Standard Work
This is an unedited replay of a previous Lean 911 episode, originally published on January 13, 2023. We're bringing it back because the issue still causes Lean transformations to stall, drift, or flatline. One of the most misunderstood parts of Lean, Standard Work, is often dismissed as...
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The Six Sigma Hysteria
In this episode, we dive into the rise, dominance, and controversy surrounding Six Sigma — the corporate improvement system that promised near-perfect quality and became a management obsession across America. From Motorola's statistical revolution to Jack Welch's aggressive rollout at General...
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Your Machines Are Lying to You, and So Are Your Equipment Vendors – The Hidden Waste Most Manufacturing Engineers Ignore
Manufacturing Engineers pride themselves on precision, but what if the biggest waste is hiding in plain sight—inside the equipment itself? In this episode, we challenge the status quo: excess feeds, slow speeds, and bloated cycle times that no one questions. Even worse, capital equipment is often...
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What a Fighter Pilot Can Teach You About Selling Lean Value – with Randy Fitzhugh
In this powerful episode of Lean 911, Mark DeLuzio sits down with former Air Force fighter pilot and Danaher sales leader Randy Fitzhugh to unpack the real science behind value selling and why most organizations get it wrong. Drawing from his elite military background and executive experience,...
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Standards Written in Blood – There May Be No Second Chance
Lean management teaches that standards are the foundation of safety, quality, and improvement. In aviation, those standards take the form of checklists, redundancies, procedures, and strict cockpit protocols designed to prevent human error. In this episode, we examine the tragic aircraft accident...
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The CFO vs. Lean: The Fight That Gets Lean Leaders Fired
Mark DeLuzio, the Father of Lean Accounting, tells his experience and observations on how traditional cost accounting will derail a Lean Transformation. In many organizations, Lean transformations don't fail on the shop floor—they fail in the finance office. In this episode, "The CFO vs. Lean…
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The Illusion of Business “Logic” – Brilliant at Home, Illogical at Work
In this episode, you'll be able to take away why many "logical" workplace measures and incentives can drive behavior that conflicts with Lean principles, and why comparing work decisions to everyday home-life decisions can make Lean concepts easier to understand and teach. You will hear about...
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Book Review – Accidentally Aligned with Jason Neal
A shop floor comment stops everyone in their tracks: the work finally matches what the customer actually needs. That is the spark behind Accidentally Aligned, and it opens a bigger issue most leaders dodge: alignment does not come from posters, audits, or a new playbook. It comes from how leaders...
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Are You Set Up to Win? – Find Out Here!
Most Lean efforts do not stall because people hate improvement. They stall because the system was never built to support it. This episode gives you a fast, practical lens for evaluating whether your organization is built to sustain improvement. You will learn how to recognize common traps that…
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Stop Misusing the 2-Bin Kanban System
Mark DeLuzio discusses how the 2-Bin Kanban is meant to ensure the operator does not run out of parts. Find out why it should not be used to structure your primary Kanban system.
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Let’s Make 2026 a Year of “Return to the Basics”
Mark DeLuzio discusses the confusion that exists in the Lean Community, and the Lean Consulting industry and academia are primarily to blame. Returning to Lean Basics and ignoring distractions like Kata, Gemba Walks, Lean certifications, and other consulting “innovations,” which are designed to...
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Where Are The Engineers?
Mark DeLuzio discusses the absence of engineers from the Gemba in both manufacturing and design. He also discusses the sin of engineering, which he calls "Catalogue Engineers."
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Do You Really Understand the Toyota Production System House?
Mark DeLuzio discusses how the TPS House is not a set of tools, but a way of thinking, and that the tools of Lean support these principles. Starting with the tools before understanding the principles has proven to be the downfall of many companies starting a Lean transformation.
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How Do You Price Your Product?
Mark DeLuzio discusses the dangers of cost-based pricing as well as the various issues encountered when doing so. He introduces the merits of market-based pricing instead.
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Stop Measuring Productivity
Mark DeLuzio discusses the dangers of focusing on the lagging indicator of productivity and suggests we turn our attention towards improving our processes, which will, in turn, drive improved productivity.
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Institutionalized Waste from Mura and Muri
Mark DeLuzio discusses the institutionalized waste of Mura and Muri, and if left unchallenged, it will derail a Lean transformation.
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Lessons from the Danaher Business System Office III – Humble Errors: Mistakes We Made when Creating the Danaher Business System
Mark DeLuzio discusses the errors made when architecting the Danaher Business System and the things he would do differently today.
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Lessons from the Danaher Business System Office II – The Role and Structure of a Lean Office
A lean office can either accelerate transformation or quietly undermine it. The difference often comes down to trust, leadership alignment, and a clear sense of purpose. Drawing on his time as the architect of the Danaher Business System, Mark shares hard-earned lessons about what makes a lean...
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Lessons from the Danaher Business System Office I – Do You Have a Purpose?
Many Lean transformations commence without understanding why, and the communications to employees are poor or nonexistent. Mark DeLuzio talks about this failure mode and why it is essential to answer the question, “What’s in it for me?”
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Problem Solving IX – Are you a Critical Thinker? The Mindset of a Problem Solver
Mark DeLuzio discusses the rules and mindset needed to be an effective critical thinker, which is essential to effective problem-solving. Every Lean coach needs to know how to solve problems effectively. Unfortunately, this knowledge is not widespread. Learn the skills required to take your...
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How Compensation Systems Can Kill a Lean Transformation
If your Lean transformation feels like it's stuck, your compensation system might be part of the problem. In this episode, Mark tackles a question from Finland about how incentives influence behavior, often in ways that completely undercut Lean principles. He shares how traditional pay structures...
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Why the Danaher Business System Was Successful – The Answer May Surprise You!
Mark DeLuzio discusses the intangibles that made all the difference to the success of the Danaher Business System. He also discussed the main ingredients of DBS, the 5Ps: Purpose, Principles, People, Plan, Process.
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The Problem with OEE and Absorption Accounting
Some metrics were never meant to survive in a Lean world. OEE and absorption accounting might sound smart on paper, but they push the exact behaviors that wreck flow, bury quality issues, and inflate inventory. The result? A system that looks efficient but delivers chaos. Mark DeLuzio breaks down...
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Lean Leadership Mistakes That Stall Change (Webinar Replay Ask Two Marks Anything)
Replay from our live April 7 webinar. Most Lean initiatives stall because leaders chase tools instead of building capability. In this rare unfiltered session, Mark DeLuzio teams up with seasoned transformation veteran Mark Forkun for a blunt conversation on the realities of Lean, why most...
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Problem Solving VIII – Defining the Span of Control to Enable Problem Solving
In this episode, Mark DeLuzio talks about Lean Horizons' Managing Director Jon Boucher discussing the span of control necessary for problem-solving. In particular, Mark and Jon address the following: What is span of control, and why is it important for any lean journey Problem Solving – What is…
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Why Don’t Your Leaders Listen to You?
In this episode, Mark DeLuzio talks about why Lean/CI people are not being listened to and gives sage advice as to how to reverse this trend.
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Mark’s Favorite Lean Financial Metric – Free Cash Flow as % of Net Income
Do you want to get the attention of leadership? Then you need to speak their language. In this episode, Mark DeLuzio discusses FCF %NI and why this measure is key to a successful Lean transformation.
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Death by Point Kaizen – Why You Need Kaikaku
You will never transform your company by point kaizen alone. Learn why traditional Japanese consultants were not enough in order to propel Danaher into a space all by themselves. Kaikaku (radical change) was a hallmark of Danaher’s Strategy Deployment process.
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The Games We Play With On-Time Delivery Metrics
Mark discusses how companies develop On-Time Delivery KPIs (OTD) that do not reflect the customer's needs. Learn how Mark calls these "Watermelon KPIs" – GREEN on the outside and RED on the inside. Do your OTD metrics truly drive customer satisfaction?
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Target Costing – Make Money on Job #1
Mark discusses building profitability into the design process via the Target Costing methodology. Roughly 70% of a product’s cost is baked into the product's design and process, leaving only 30% to Kaizen (post-design). Learn from Mark’s experience as CFO of Danaher’s JAKE Brake, where Target...
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Why Aren’t There More Value Stream Organizations?
Mark talks about the types of Value Stream organizations and their benefits. But why are organizations reluctant to move to a Value Stream structure? Mark discusses the reasons why.
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Jerry Wright – Book Review: “The Insanity Trap – What Your MRP Consultant Won’t Tell You”
Mark talks with Jerry Wright on his new book about the ills of MRP. Jerry talks about his experience of seeing failure after failure with companies trying to perfect MRP. He argues that a Lean Transformation is impossible if MRP is used as the primary resource planning tool. MRP was first...
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Griselda Abousleman – The Power of Optimism
Mark talks with an esteemed Lean colleague, Griselda Abousleman, whose life story should be an inspiration to all minority women, as well as to all of us who are struggling to make it in this world. Her incredible story is chronicled in her newly released book, “From the Border to the Boardroom.”...
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How Do You Define a Defect?
Most people define defects based on an engineering product specification. There is nothing wrong with this. However, in this episode, Mark DeLuzio explains why we need to broaden our thinking when it comes to defining defects.
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The Productivity Hysteria
Are you focusing on productivity as your barometer of Lean improvements? Mark DeLuzio discusses why this approach may be leading your Lean transformation into a brick wall.
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Death by Lean Audits
Have you ever wondered why a supplier is auditing their "customer?" Mark discusses the ills of Lean Audits and the destructive culture created by those executing these audits.
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Generational Yokoten
It appears that the Lean Community has lost its way from the originators of Lean…that is, Toyota. Mark DeLuzio discusses the many reasons why and points out the need for us to get back to basics.
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Respect for People with Nathan Corliss
Nathan Corliss joins Mark DeLuzio to discuss the crucial topic of respect for people within lean transformation processes. As they navigate through personal anecdotes and professional insights, they discuss the significance of understanding and valuing employees' contributions and the principles…
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The Way of Lean Investing with Cliff Ransom
Ever wonder what a Lean Investor thinks? What they see? The questions they ask? Probably not, since there are so few in existence. In this episode, Mark talks with his long-time friend and colleague of 34 years, Cliff Ransom, of Ransom Research. As a Wall Street Analyst, Cliff covered Danaher,...
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The Poison of Metrics – With Jon Boucher
Like many poisons, they initially taste good. However, over the course of time, the poison will be your ultimate demise. Mark and Jon talk about how our metrics drive behaviors that fly in the face of Lean principles. Most metrics today do little to truly solve a problem. Traditional accounting,...
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The 7 Flows – With Jon Boucher
Learn about the 7 Flows of Manufacturing as taught by our Sensei Chihiro Nakao of Shingijutsu. Jon takes us through The 7 Flows, which are easy to understand. However, not all that easy to implement. These concepts are a must if you are to call your operations “Lean.”
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Why The Theory of Constraints (TOC) Was Not Included in the Creation of DBS
Mark discusses why TOC was not included in the framework of DBS and how TOC is in conflict with fundamental Lean principles. In the final analysis, it was determined that TOC offered nothing unique when compared to Lean and had the potential to drive the wrong behaviors while creating mass...
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ABOUT THIS SHOW
The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.
HOSTED BY
Mark DeLuzio
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Frequently Asked Questions
How many episodes does Lean 911 have?
Lean 911 currently has 92 episodes available on PodParley. New episodes are automatically indexed when they're published to the podcast feed.
What is Lean 911 about?
The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most...
How often does Lean 911 release new episodes?
Lean 911 has 92 episodes. Check the episode list to see recent publication dates and frequency.
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You can listen to Lean 911 on PodParley by clicking any episode. We provide an embedded audio player for direct listening, and you can also subscribe via your preferred podcast app using the RSS feed.
Who hosts Lean 911?
Lean 911 is created and hosted by Mark DeLuzio.
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