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Lean thinking is often associated with manufacturing floors, production lines, and complex value stream maps. Yet waste exists in every type of process. Once you begin to see it, y...
TL;DR: The eight wastes give you a lens for seeing problems — but Lean isn't a scavenger hunt for waste. The real work is understanding why waste exists and building systems where...
Before I get into the focus of this column, I’d venture to guess that many quality professionals reading this column’s title did an about take thinking this guy has lost his mind....
Production delays, excess inventory and inconsistent workflows can quickly reduce output and increase operating costs. The right lean manufacturing tools and techniques help manufa...
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...
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...
When Lean Isn’t Enough A journey through bottlenecks, contradictions, and breakthroughs Mark Hembree Thu, 04/16/2026 - 12:03...
The medical supply industry is the business of supplying the healthcare industry with items such as surgical instruments, bandages, general wound care, gloves, staff and patient ap...
This week’s guest is Randall Dupre. Ron and Randall discussed Randall’s book, “Everyday Lean,” the kinds of mistakes Randall sees people making, what good leadership looks like, hi...
5 Shop Floor Problems That Drive Customers Away And how to make the trouble disappear Mark Hembree Thu, 04/02/2026 - 12:02...
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...
Making the transition to right-sized packaging minimizes waste and improves efficiency. When a box fits the product, there’s less waste and less risk of damage to the product. The...
Most improvement work starts with a process someone can see: the steps their team follows, the metrics on their board, the problems in their inbox. That's where it should start....
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...
Most warehouse delays don’t come from big problems; they come from small ones that keep repeating.
A food company had a flowchart any auditor would love. Every step mapped. Every step mapped. Every critical control point identified. The HACCP plan (Hazard Analysis and Critical C...
Establishing a 5S toolkit store room for an 820 MW solar plant requires strict organization to ensure safety (high tension/HT and low tension/LT), tool calibration accuracy, and m...
One operations director, describing what happened to frontline ideas at his organization before they overhauled their approach, put it this way: "The employees felt like the...
Walk through almost any manufacturing facility and you’ll see a familiar story: machines placed where they’ve always been, workarounds layered on top of old decisions, and material...
The rising costs of running a warehouse business, hiring and retaining employees, and margin pressure create great strain on wholesalers and their retailers. In the quest for wareh...
Some Hazardous Ideas And why they are wrong Donald J. Wheeler Thu, 05/28/2026 - 12:03 Off...
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...
A new LeanDNA study finds most supply chain failures happen after the plan is set, costing manufacturers time, money, and trust.
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