Even Ohno’s Classic “5 Whys” Example Deserves Another Why
Here's the most famous example of root cause analysis in the Lean world, from Taiichi Ohno's book on the Toyota Production System. You've seen it in training decks, conference talk...
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Here's the most famous example of root cause analysis in the Lean world, from Taiichi Ohno's book on the Toyota Production System. You've seen it in training decks, conference talk...
If your Five Whys sessions feel like they’re going in circles, you’re not alone. What starts as a simple exercise often turns into a tangled mess of guesses, side paths, and compet...
You know the feeling in the conference room when the team finally lands it. The fishbone is covered in sticky notes. You've worked through five whys, or ten, or fifteen. Somebody o...
The post below was written by Gemba Academy Master Black Belt Candidate Noah Waech. Noah was also recently on our podcast. Thank you for sharing your knowledge with us, Noah! Roo...
You’ve been here before. A defect surfaces and brings a critical project to a halt.
5 Shop Floor Problems That Drive Customers Away And how to make the trouble disappear Mark Hembree Thu, 04/02/2026 - 12:02...
Lean has a decades-long track record of producing real results across industries. Hospitals have used it to reduce patient harm and eliminate hours of wasted time per shift. Manufa...
Two questions from a few Toyota mentors — and the Deming idea behind them. You can usually feel it before you can name it. The improvement meeting that used to feel alive is now… p...
В Incident Investigation: Learn From Today, Prevent TomorrowCaption:Every incident has a cause. Every cause can be prevented.В But only if we investigate it the right way.The 7-Ste...
Here's something that happens every day in your organization: someone solves a problem. A workaround for a broken process. A fix for a recurring error. A clever adjustment that...
When Things Go Wrong What happens next Donald J. Wheeler Mon, 04/20/2026 - 12:03 Off...
You finish the project. The numbers look good. Your process is faster, your team is relieved, and you move on to the next thing. Then, twenty minutes into the next meeting, some...
Every improvement program has a version of this story. Someone identifies a change they want to make. They build the business case, get the resources, run the project. The resul...
In 2007, I wrote about a BBC article that included a number I've never quite been able to shake. Workers at Toyota's Georgetown, Kentucky plant were pulling the andon cord – the me...
There is a question we ask almost every day, yet rarely stop to examine its underlying logic: why.Continue reading on Medium »
You already know something is broken. The spreadsheet that tracked 40 improvements just fine is now a 12-tab monster maintained by a person who might leave next quarter. The sug...
Worrying about a problem reduces our ability to focus 100% of our attention on the task. One way to focus your attention is to answer the following questions. 1. What exactly is...
設計品質と量産品質の構造を整理し、品質不良が生まれるメカニズムを体系的に考察する連載「製品リコールを生む品質不良の原因と対策」。第4回では、設計プロセスで「完璧な設計」が実現できな...
If there is one concept that kept resurfacing across the Ask Us Anything sessions -- even when we were not using the formal term -- it was this: why don't people speak up? Some...
Gotcha Walks A gemba is for learning, not blaming Mark Hembree Wed, 05/13/2026 - 12:03 Off...
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