Lean by Doing

Joel from our customer service team talks about his trip to the Siouxland Lean Consortium 2026 and what he learned from several lean tours in Iowa.

Edwin Proper visits all the way from Australia to see our operation, give feedback and help us problem-solve. He shares the good and the areas he sees for improvement after being with us for two weeks.

Joe sits down to talk about his incredible change from before Lean to now and encourages anyone out there to do the same!Chapters00:00 Introduction and Fresh Perspectives04:03 Joe's Transformation Journey07:21 The Shift in Leadership Dynamics10:10 Empathy vs. Compassion in Leadership13:04 The Importance of Mentorship16:19 Unlocking Potential in Employees19:15 Leadership Styles and Personal Growth22:10 Challenges and Learning from Failures24:57 Conclusion and Call to Action

The great people from Die Co. stopped by for a lean tour, and Brady Neuhart sat down to talk about their new lean implementation in an employee-owned company.Chapters00:00 Introduction to Lean Transformation and Employee Ownership03:13 The Journey of Lean Implementation at Dyco06:09 Financial Literacy and Employee Engagement09:33 Overcoming Resistance to Change12:20 Building a Culture of Ownership and Accountability15:16 Guiding Principles for Employee Owners18:09 The Role of Leadership in Lean Transformation21:28 Connecting Work and Family24:22 Conclusion and Future Aspirations31:08 Introduction to Leadership Insights31:31 The Lean Leadership Action Guidebook Overview

In this conversation, Brian and Joey discuss their evolution as leaders and their different styles. They explore the challenges of setting a clear vision, balancing strategy with execution, and the need for continuous improvement in leadership approaches. The dialogue emphasizes the significance of fostering a supportive environment that encourages employee engagement and growth while maintaining high standards.Chapters00:00 Introduction02:55 Transformation and Environment06:01 Leadership Styles and Approaches11:38 Vision and Clarity in Leadership17:46 Balancing Strategy and Execution23:37 Challenges in Leadership and Culture29:38 Actionable Takeaways and Conclusion

This week on the Lean by Doing Podcast, Brian talks with Chris Hamilton about how our Lean implementation has changed his work, confidence, and daily life.Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-up

Andy Olrich visited all the way from Australia, got a tour of our new facility, and shared some of his insight on shop floor metrics and goal measurement.

Tom is back, this time to tour our new facility just a week after we moved in.

In this conversation, Willie Peters from Lamar Trailers shares insights into the company's journey, emphasizing their faith-based values and the importance of operational excellence through Lean principles. He talks about the challenges faced in implementing Lean in a large company (200+ employees).00:00 Introduction to Lamar Trailers02:32 Faith-Based Business Values05:33 The Lean Journey Begins08:26 Implementing Lean Practices11:46 Challenges in Lean Adoption14:35 Struggles with ERP Systems17:26 Innovative Solutions and Kanban20:36 Reflections on Lean Successes and Failures23:28 Future Directions and Closing Thoughts

Brian talks about recent life updates, time off, and keeping the rope tight with Lean. Keep the rope tight on your processes, not too tight on people.Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-up

In this episode of Lean by Doing, I dive into the complexities and challenges of implementing ERP systems in lean manufacturing environments. While ERP systems are often seen as solutions to a wide range of business problems, I’ve found that they can actually introduce significant inefficiencies and hidden costs. Drawing from my own experiences, I talk about the importance of data integrity, the potential for waste, and why businesses need to critically assess their reliance on ERP systems. I also suggest exploring alternatives like AI and lean methodologies before fully committing to an ERP solution.Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-upChapters00:00 Understanding ERP Systems in Lean Manufacturing05:46 The Limitations of ERP Systems13:59 Practical Recommendations for ERP Users

This week, we hosted our first AME 2 Second Lean Tour. One of the best questions was "Brian, what does a typical day look like for you?". I didn't get a chance to answer it then, so this week I talk about what my day looks like as a lean leader and the changes I made to get to this point. I hope this helps you in your lean journey!00:00 Introduction to Lean Transformation04:09 The Shift in Leadership Approach04:13 Embracing the GEMBA05:03 Maximizing Existing Sales05:47 Structuring the Day for Success07:58 The Importance of GEMBA Walks10:09 Coaching for Continuous Improvement12:06 Creating Lean Content and Its Impact

In this episode, I talk about my personal experience implementing lean at Fat American Manufacturing. Here are 3 traps to watch out for and 3 tips to help you in your lean implementation. I hope this helps you and your business. If you have any tips, wisdom, experiences...leave them in the comments, they can help us all learn!Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-up

In this episode, Brian discusses his personal struggles with Lean implementation, focusing on five key areas: distractions from a new building project, missing KPIs, staff development challenges, the gap between expectations and reality, and the busy culture affecting leadership transitions. He emphasizes the importance of continuous improvement and the frustrations that come with managing a team while striving for Lean excellence.

Brian shares his incredible lean adventure across Ireland, where he and his colleague explored various businesses implementing lean practices. They visited seven companies, each showcasing unique approaches to lean, from office organization to manufacturing processes. The journey highlighted the importance of developing people, embracing lean culture, and the community's eagerness to learn and improve. Brian reflects on the insights gained and the potential for lean practices to transform businesses in Ireland, making it a relatable model for others.Check Out the Businesses We Visited:Adman Steel ShedMurphy Precast Concrete Applied Concepts ATC Advanced Technical Concepts Seating Matters SDC Trailers Hampton Conservatories

This week, Brian and Chris discuss the journey of Command Electronics in implementing lean manufacturing practices. They explore the challenges faced during the transition, the importance of building a lean culture, and the impact of COVID-19 on their operations. Chris shares insights on improving lead times, quality control, and fostering team engagement through morning meetings and continuous improvement initiatives. The discussion highlights the significance of collaboration and innovation in the manufacturing industry, as well as the future goals of Command Electronics in expanding their lean practices.Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-upChapters00:00 Introduction and Backstory03:41 The Evolution of Command Electronics06:55 Challenges and Changes in Manufacturing09:43 Implementing Lean Manufacturing Practices12:38 Building a Lean Community15:55 Lessons Learned from Lean Implementation19:10 Navigating Market Challenges21:34 Innovations in Product Development25:50 Quality and Lead Time: The Key to Success31:05 Embracing Lean: The Journey of Continuous Improvement35:45 Building a Culture of Trust and Transparency41:27 Future Growth: New Opportunities and Challenges46:16 Collaboration and Communication: The Lean Advantage51:12 Exploring Lean Principles with Chris Campagna51:16 Exploring the Lean Toolkit

Brian discusses the challenges and innovations in implementing Lean practices within a business, particularly focusing on the hiring process. He sits down with new employee, Wyatt, to discuss the importance of trial days, standard work, and continuous improvement in creating a culture that aligns with Lean principles. They highlight the need for adaptability in hiring and onboarding processes to ensure a good fit for both the company and the employees.

Brian talks with Alex, the engineering manager, about the journey of the engineering team transitioning from traditional practices to Lean methodologies. It highlights the challenges faced in a conventional engineering environment, the implementation of Lean tools, and the cultural shifts within the team. The discussion also delves into product development, continuous improvement, and aligning the company's vision and mission with engineering practices.00:00 Introduction and Background03:37 Career Journey and Early Experiences06:22 Challenges in Engineering Before Lean09:28 Transition to Lean Methodology12:35 Implementing Lean in Engineering15:22 Cultural Shifts and Team Dynamics18:19 Product Development and Design Improvements21:39 Adapting to Shipping Challenges24:27 Continuous Improvement and Customer Focus27:19 Vision and Mission in Product Development30:26 Case Study: Land Cruiser Bumper Redesign33:20 Final Thoughts and Future Directions42:00 Exploring the Lean Toolkit

In this episode of the Lean By Doing podcast, Brian and his guest Brian Schreuder discuss the journey of lean transformation within their organization. They explore the challenges of implementing lean practices, the importance of leadership in fostering employee engagement, and the impact of kaizen events on workflow efficiency. The conversation delves into the nuances of navigating change, resistance from employees, and the significance of value stream management. They also touch on the necessity of training and development in lean practices, creating a culture of continuous improvement, and the importance of building relationships in the workplace.Chapters00:00 Friendship and Collaboration03:09 The Lean Transformation Journey06:12 Kaizen Events and Workflow Improvements09:08 Shifting Roles and Responsibilities12:30 Challenges of Leadership and Team Dynamics15:28 The Balance of Push and Pull in Management18:26 Hiring and Firing in Lean Culture21:15 The Importance of Continuous Learning24:15 Value Stream Management27:08 Engaging Employees in Improvement30:21 Building a Positive Work Culture33:14 Looking Ahead: Future Improvements

This week, author & lean expert Chad Bareither stopped by with some hard-to-hear feedback! Brian and Chad discuss the challenges and strategies of implementing Lean practices in a business environment, with a strong emphasis on safety, leadership, and the importance of developing a culture of continuous improvement. They explore the current state of Lean implementation, the necessity of safety standards, and the role of leadership in guiding teams towards strategic goals. The discussion also highlights the balance between tools and people in Lean practices, as well as the need for a supportive culture that encourages ownership and accountability among team members.Get Chad's Book!https://amzn.to/3XLof8TGet a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-upChapters00:00 Introduction to Chad Bereither and His Work03:26 Consulting and Strategy Deployment Simplified06:16 Lean Implementation and Current State Assessment09:31 Safety Standards and Organizational Culture12:20 Leadership and Strategic Focus15:11 Sustaining Improvements and Leadership Development18:29 The Importance of People Over Tools21:17 Mentorship and Team Development24:04 Embracing Change and Continuous Improvement27:21 Conclusion and Future Directions

A step-by-step guide to building a team of 'Lean All-Stars'. Leaders to implement lean in your business. This process will turbocharge your lean implementation and spread it through your organization organically!Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-upChapters00:00 Turbocharging Lean Implementation00:58 Building a Lean All-Star Team01:20 Creating a Culture of Continuous Improvement01:32 Qualifying Lean All-Stars02:08 Encouragement and Constructive Feedback03:14 The Mission of Lean All-Stars03:51 Strategic Execution and Alignment04:53 Requirements for Lean All-Stars05:29 Accountability and Peer Support06:24 Benefits of Being a Lean All-Star06:50 Building a Lean Culture through Mentorship

In this episode of the Lean By Doing podcast, host Brian engages with lean expert and implementation consultant Patrick Adams to explore the principles of lean transformation, the importance of leadership engagement, and the necessity of continuous improvement in organizations. They discuss the ideal customer for lean practices, the role of education in implementing lean strategies, and the significance of personal touch in customer engagement. The conversation emphasizes the need for innovation and adaptability in business and creating a culture that empowers teams to drive improvements. The episode concludes with insights on setting priorities and establishing leader standard work to foster a continuous improvement environment.Get a FREE Lean Resource Kit with tools for your Lean implementation!https://www.leanbydoing.com/resource-kit-sign-up00:00 Introduction to Lean Solutions and Continuous Improvement02:47 Identifying the Ideal Customer for Lean Transformation05:59 The Importance of Leadership Engagement in Lean08:47 Employee Engagement and the Lean Journey12:05 The Role of Education in Lean Practices14:58 Observations from the Lean Tour18:11 Customer Engagement and Personal Touch in Business20:51 Growth and Brand Development in Lean Organizations24:13 Navigating Market Changes and Customer Needs27:30 The Importance of Innovation and Customer Connection30:14 Streamlining Operations for Customer Satisfaction33:06 Empowering Teams for Continuous Improvement36:22 Establishing Structure for Lean Practices39:39 Creating a Culture of Engagement and Purpose44:30 Exploring Lean Leadership Concepts

Here is the story of my trip with Mazak to Japan and Europe, which introduced me to Lean Manufacturing and has completely changed my business, life, and work culture.Learn more about Lean Manufacturing:https://www.leanbydoing.com/https://paulakers.net/books/2-second-leanhttps://improvementstartswithi.com/Chapters00:00 Brian's Origin Story and Introduction to Lean00:00 Transformation Through Lean Principles00:14 Journey to Japan: First Impressions03:40 Cultural Insights and Lean Manufacturing Experience04:59 Capturing Lean Tools in Action04:59 Understanding the Implementation of Lean Tools05:21 The Lean Culture of Japan05:51 Challenges of Implementing Lean in the U.S.07:06 Discovering Lean Principles in Europe07:28 Reflecting on Japanese Influence07:42 The Journey to Lean Implementation09:06 Introduction to Continuous Improvement Culture09:06 Implementing Two Second Lean09:31 Embracing Lean Principles09:47 The Spark of Innovation10:07 The Desire for Transformation10:08 Overcoming Challenges in Business10:24 The Lean Transformation Journey10:32 Transformative Journeys: A Business Evolution10:33 Cultural Insights: Learning from Global Experiences

In this conversation, Brian and Will discuss the implementation of Lean practices in business operations, focusing on leadership, team engagement, and the challenges faced in food safety. They share insights on creating a strong workplace culture, the importance of feedback, and the role of mentorship in leadership development. The discussion highlights the transformation of leadership styles and the significance of recognizing and appreciating team efforts, ultimately emphasizing the need for effective communication and continuous improvement in the workplace.

Brian discusses the significance of value streams in manufacturing and how to effectively build and manage them. He emphasizes the importance of creating teams that operate like small businesses, focusing on specific product groupings to enhance workflow and productivity. Brian shares practical steps for implementing value stream mapping, daily operations, and the positive outcomes of these practices, including increased employee engagement and improved efficiency.

In this episode, Brian interviews Morgan, the Chief Visual Control Officer, about her journey from being a welder to embracing a creative role in marketing and visual control. They discuss the challenges of implementing Lean methodology, the impact of ADHD in the workplace, and the importance of fostering a supportive environment for creativity and personal growth. Morgan shares her experiences, the tools she developed to manage her ADHD, and the transformative effect of external validation on her confidence and creativity.

In this episode of the Lean By Doing podcast, Brian and Casey discuss their journey in implementing lean management practices within their production environment. They share insights on the transition to lean, the introduction of turnback boards for problem documentation, and the importance of root cause analysis. The conversation highlights the challenges and successes they've experienced, emphasizing the need for accountability and continuous improvement in their processes. In this conversation, Brian and Casey discuss the importance of identifying root causes in manufacturing errors, the implementation of standard operating procedures (SOPs), and the transformative impact of lean strategies on business efficiency. They explore job sequencing and load leveling in production, emphasizing the need for accountability and leadership development within the manufacturing process. The discussion highlights the shift from reactive problem-solving to proactive measures that enhance overall productivity and employee engagement.Chapters00:00 Introduction and Background of Casey02:20 Transitioning to Lean Management05:42 Implementing Turnback Boards09:04 Understanding Turnbacks and Their Impact15:39 Root Cause Analysis and Accountability20:03 Future Goals and Continuous Improvement24:50 Identifying Root Causes in Manufacturing Errors27:38 Transformative Business Practices: Standard Operating Procedures29:36 Implementing Lean Strategies for Efficiency32:40 Job Sequencing and Load Leveling in Production35:54 The Importance of Leadership Development in Manufacturing

In this conversation, Brian and Bryce discuss the transformative impact of Lean manufacturing on their production processes and personal growth. They explore the challenges of identifying and addressing bottlenecks, implementing Kanban systems, and the importance of leadership development within the team. The discussion highlights the evolution of workflow efficiency, the significance of feedback in leadership, and the future goals for continuous improvement in their operations.Chapters00:00 Introduction to Lean and Personal Growth03:20 Understanding Production Bottlenecks06:15 Transitioning to Lean Manufacturing09:39 Challenges and Adjustments in Lean Implementation12:32 Leadership Development and Team Dynamics15:21 Kanban System and Inventory Management18:18 Feedback and Continuous Improvement21:39 One Piece Flow and Operational Efficiency27:23 Navigating Production Challenges30:49 Strategies for Reducing Backlog32:46 Implementing Kanban for Efficiency36:03 Future Goals and Improvements38:54 Team Development and Leadership40:52 The Golden Banana Award and Recognition

In this episode of the Lean by Doing podcast, Brian talks with Mike & Mike from Globex Performance, who share their journey in the automotive industry and their struggles with growth. They discuss the importance of customer relationships, observations from a Lean tour, and the cultural shifts needed to empower employees. The conversation delves into implementing Lean tools, the challenges of creating Standard Operating Procedures (SOPs) for skilled positions, and the integration of Lean principles in material purchasing. The guests express excitement about their Lean journey and the positive changes they anticipate.

In this episode of the Lean By Doing podcast, host Brian talks with Kevin Rikkers, General Manager at JCR, to discuss their journey of implementing Lean practices over the past six months. They explore the initial impressions of Lean, the significance of value stream mapping, the restructuring of teams for better management, the identification of Kaizen events for continuous improvement, and the importance of engaging team insights to tap into unutilized talent.