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Wednesday, August 13, 2025

Book Review: Lean Made Simple

I just finished reading Lean Made Simple by Ryan Tierney which is an excellent guide for anyone looking to implement Lean principles in a practical and straightforward way. Ryan breaks down the concepts into actionable steps that are easy to understand and apply, even for those just starting their Lean journey.

Ryan Tierney leads operations at small, family run business making medical chairs with his brothers in Northern Ireland. After some business struggles and looking for answers Ryan came across Paul Aker’s videos about 2 Second Lean which turned his intrigue in Lean to a fascination.

Ryan documents the steps he took to create a vibrant, world-class Lean culture that has attracted the attention of industry leaders from around the world including Toyota, Lexus, Coca Cola, Caterpillar and even Royalty!

By doing the basics consistently and committing to these 12 steps you will be able to positively impact the people you serve, your organization and your community.

Step 1 – It starts with the leaders

Step 2 – Hold a morning meeting

Step 3 -Create a Lean leaders group

Step 4 – Create an example area

Step 5 – Teach your people to see waste

Step 6 – Introduce improvement time

Step 7 – Introduce yokoten

Step 8 – Make improving easy

Step 9 – Solve your inventory problems

Step 10 – Create standard operating procedures

Step 11 – Implement total ownership

Step 12 – Connect with other Lean enthusiasts

 Each chapter has Ryan’s recommendations, answers to burning questions, and prompts to make you think about your own organization to get you started creating your Lean culture. Ryan also shares a number of resources with QR codes to further your learning like podcasts, YouTube videos, and other literature at LeanMadeSimple.com/bookresources.

A very easy to read book at only 152 pages, this is a quick read in about 90 minutes. Ryan packs this book full of simple but very practical and highly effective tips to start the transformation of any company towards a more engaging, more efficient, more fulfilling place to work. 

This is a must-read for anyone wanting to transform their organizational culture.

Get your copy here.










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Monday, August 11, 2025

End the Blame Game


Workplaces that assign blame to individuals rather than looking at organizational issues create an environment where people are afraid to speak out, are defensive, and are unable to be creative. From healthcare and banking to technology and manufacturing, blame culture negatively impacts on employee engagement, productivity, and can result in lost chances for improvement.

The blame culture is woven into the fabric of many organizations. This phenomenon involves assigning fault to individuals when errors occur, rather than addressing systemic issues. It’s a culture where finger-pointing trumps collaborative problem-solving, and fear of retribution stifles voices that could propose innovative solutions.

The blame culture is a reflexive, defensive posture that can suffocate creativity and hinder progress. As you’ll see, the blame culture is antithetical to nurturing trust and fostering an environment conducive to experimentation and learning. Leaders must navigate this delicate balance between accountability and the detrimental effects of blame.

If a blame culture is a norm at your company, it’s time to make a change. Here are 5 tips to help you stop a blame culture and cultivate a healthier, more supportive work environment:

1.     Change Your Mindset

Blame is biological. It’s inherent in our DNA to want to shift blame onto others.

The good news is that you can reduce the frequency with which you blame others — and improve the culture at your work — by changing your mindset.

Don’t automatically look for someone to blame or ask who’s at fault when you have a poor outcome.

Instead, make a phrase like “We’re all learning” or “We’re all in this together” your mantra. Write it down and display it on your desk, so you don’t forget.

Shifting your mindset might seem impossible at first. With practice, though, it’ll soon become second nature.

2.     Lead by Example

To change the culture at your company, you must lead by example. You can’t create an environment where your employees feel comfortable taking responsibility for their mistakes if you never own up to yours.

Start by sharing your mistakes with your team. Talk about what you learned when you “messed up” and explain the steps you took to avoid messing up again in the future.

When you share your mistakes, you send a signal to your employees that it’s safe for them to share theirs. This approach creates a more psychologically safe workplace and contributes to a no-blame culture.

3.     Foster Transparency

When you share your mistakes, you contribute to a culture of openness and transparency at work.

Continue this trend by regularly inviting feedback from employees. Give them time during meetings to talk about their recent wins, the problems they’ve encountered, and the issues holding them back from progressing.

When you create a safe place for employees to talk about their problems and pain points, as well as the progress they’ve made, you foster a more transparent workplace and a more engaged team.

4.     Change the Way You Address Mistakes

Treat mistakes as learning opportunities. Rather than viewing them as setbacks, look for ways to turn them into lessons for your team and yourself.

It’s always better for your employees to come to you immediately when something goes wrong rather than wasting time and resources trying to cover up their mistakes.

Suppose an employee knows you won’t yell at them, threaten to fire them, or embarrass them for messing up. In that case, they’ll be more inclined to take responsibility.

Sharing their mistakes also allows them to fix and learn from the problem faster.

5.     Encourage Empathy

Empathy is at the core of a no-blame culture.

Remember that no-blame cultures are built around an understanding of human complexities and the complexities of their jobs. A no-blame culture acknowledges that mistakes can happen and views them as valuable data rather than moral failings.

If you want to eliminate a blame culture at work, start practicing and encouraging empathy. Put yourself in your employees’ shoes and invite them to do the same.

An essential aspect of empathy is active listening. Active listening goes beyond simply hearing what someone is saying and genuinely interpreting the meaning behind their words.

When you actively listen, it’s easier to understand why someone made a particular decision or handled an issue in a specific way. This understanding helps you see things from their perspective and become more empathetic.

If you really want a positive, productive workplace, then you’ve got to stop ‘blame culture’ in its tracks. It’s not going to happen overnight. You’ll need to be patient and persistent. You can do this by following the 5 tips you’ve just learned. Tackling blame culture leads to a happier, safer environment in your workplace.


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Friday, August 8, 2025

Lean Quote: We All Need Feedback to Improve


On Fridays I will post a Lean related Quote. Throughout our lifetimes many people touch our lives and leave us with words of wisdom. These can both be a source of new learning and also a point to pause and reflect upon lessons we have learned. Within Lean active learning is an important aspect on this journey because without learning we can not improve.



"We all need people who will give us feedback. That's how we improve.  —  Bill Gates  


Feedback provides valuable insights into our strengths and areas for growth, enabling us to learn, adapt, and become more effective in various areas of life.

Tips for giving feedback:

Make time

  • Regardless how busy you are, create a feedback calendar and take it seriously!
  • If you become aware of a “positive” or “negative” action, acknowledge it immediately


Make it honest and meaningful

  • Be prepared to provide specifics about both negative and positive feedback
  • Think in terms of praise and constructive criticism – both contribute to growth


Use goal tracking

  • If you don’t know how to get started, review how the individual has helped (or hindered) the achievement of organizational or team goals


Discuss and document the top 3 strengths and 3 growth opportunities

  • For the strengths, try to leverage them and keep them sharp
  • For the growth opportunities, determine what actions can be implemented immediately, which require assistance (ex. Training/mentoring), and have a plan for tracking progress


Commit to supporting continual learning

  • Review what in house programs are available
  • Ensure your budget adequately includes development opportunities
  • Investigate external training that can address your focus areas

 

Leaders should take the first step: Model the behaviors you want your managers to display by sharing " Feedback" with them. Help your managers provide meaningful feedback by prioritizing manager development. Then watch as your feedback culture accelerates workplace productivity and engagement.

Thursday, August 7, 2025

Lean Quote: Eiji Toyoda's Respect for People

Eiji Toyoda’s Legacy: Respect for People in the Toyota Production System

On Fridays, we reflect on powerful Lean quotes that help us pause, learn, and grow. Words from visionary leaders don’t just inspire—they remind us of the foundational principles that drive long-term success.

This week’s quote comes from Eiji Toyoda, one of the most influential figures in modern manufacturing and a key architect of what we now know as the Toyota Production System (TPS):

"…employees are offering a very important part of their life to us. If we don’t use their time effectively, we are wasting their lives."
Eiji Toyoda, Former President and Chairman of Toyota Motor Corporation

This quote isn’t just motivational—it defines one of the core Toyota Production System principles: Respect for People. Toyoda’s philosophy highlights a truth often forgotten in traditional management: time is life, and wasting it is disrespectful.


What Is the Toyota Production System (TPS)?

The Toyota Production System is a manufacturing philosophy that aims to eliminate waste, improve quality, and maximize customer value. TPS forms the backbone of modern Lean manufacturing practices worldwide.

Key Historical Milestones of TPS:

Year

Milestone

1937

Toyota Motor Corporation founded

1948

Taiichi Ohno joins Toyota and begins experimenting with process improvements

1950s

Post-war shortage leads Toyota to focus on efficiency over mass production

1960s

TPS formalized with Just-in-Time (JIT) and Jidoka (automation with a human touch)

1970s

Eiji Toyoda and Taiichi Ohno solidify Kaizen, standardized work, and respect for people

1980s

Western manufacturers begin adopting TPS practices, leading to the birth of Lean Manufacturing


TPS vs Lean Manufacturing: Understanding the Difference

While the terms TPS and Lean Manufacturing are often used interchangeably, they’re not exactly the same. Lean manufacturing is an evolution of TPS principles, adapted for broader use across industries and cultures.

Aspect

Toyota Production System (TPS)

Lean Manufacturing

Origin

Developed internally at Toyota

Derived from TPS

Focus

Elimination of waste, respect for people, JIT

Waste elimination, flow efficiency

Tools

Kanban, Andon, Jidoka, Kaizen

5S, Value Stream Mapping, A3 Thinking

Culture

Deep-rooted in Japanese work culture

Adapted to global business environments

Philosophy

Human-centered and long-term

Sometimes tool-focused in practice


Embedding Lean Into Company Culture

Eiji Toyoda’s approach to leadership wasn’t about implementing tools—it was about embedding Lean into the company culture. The "Respect for People" pillar is what distinguishes Lean culture vs traditional culture.

Traditional Culture vs Lean Culture

Dimension

Traditional Culture

Lean Culture

Leadership

Top-down directives

Servant leadership, mentorship

Communication

Hierarchical, siloed

Open, cross-functional

Learning

Training is event-based

Continuous improvement mindset

Mistakes

Punished

Treated as learning opportunities

Employee Role

Execute tasks

Solve problems, drive innovation


Eiji Toyoda and the Cost of Wasted Time

Toyoda emphasized that inefficient workflows aren’t just bad for business—they’re disrespectful to the human beings doing the work. This mindset isn’t philosophical fluff. It’s backed by data.

Time Wasted at Work: Survey Insights

A global survey of over 100,000 employees in 2,000+ companies revealed shocking stats:

Metric

Percentage

Employees who say their company uses their time wisely

12%

Employees who frequently have to ask their manager what to do

51%

Employees who can’t find what they need to do their best work

71%

Employees who think an Xbox works better than their work tools

81%

💡 These statistics reflect a failure to apply TPS kaizen and continuous improvement in the workplace.


Respect for People = Respect for Time, Skills, and Growth

One of the least discussed but most crucial Toyota Production System principles is human development. It’s easy to invest in machines or software. It’s harder—but more valuable—to invest in people.

Key Ways to Practice “Respect for People” in TPS:

  • Provide clarity: Ensure every team member knows what adds value and what doesn’t.

  • Remove barriers: Give people the tools, data, and autonomy to solve problems.

  • Develop skills: Offer on-the-job and off-the-job training to unlock their full potential.

  • Engage in Kaizen: Allow employees to lead improvements through small, iterative changes.

  • Eliminate wasted effort: Streamline meetings, approvals, and workflows.


Final Thought: Respect Is the Foundation of Lean

In remembering Eiji Toyoda, we aren’t just honoring a man who lived to 100—we're honoring a philosophy that changed the world.

If you're serious about implementing Lean, start by embracing this mindset: Respect your people's time like it’s your most valuable resource—because it is. That’s not just good leadership. That’s Lean.


Quick Action Tip:

Want to avoid becoming one of the 88% of companies disrespecting their employees’ time?
Start your week with a Gemba walk—go to the place where work happens, ask questions, listen, and learn. Then act on what you hear.



See Mark Graban’s post: Eiji Toyoda, Credited with Developing TPS and Expanding Toyota into North America, Passes Away at 100 , Bill Waddell’s post: Eiji Toyoda – the Master Innovator , Jon Miller’s post: The Man Who Saved Kaizen, and Karen Martin’s post: Eiji Toyoda: A Consummate Leader (1913-2013) for more great tributes to Eiji Toyoda.


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