The Lean Solutions Podcast

Leadership That Lasts: Respect, Stability, and the Human Side of Excellence 02.06.2026 41min

What You’ll Learn in This Episode:In this special Lean Solutions Summit episode, Patrick Adams sits down with keynote speakers Richard Sheridan, Joe Dyer, and Jason Schroeder to discuss the summit theme: Better Together: People Plus Innovation.The conversation explores the growing role of AI, automation, and technology in today's organizations while emphasizing that sustainable success still depends on people, leadership, and culture. Each guest shares their perspective on innovation, explaining why human-centered leadership, respect for people, and continuous learning remain critical regardless of technological advancements.You'll hear insights on creating joyful workplace cultures, developing a stewardship mindset, and building organizations rooted in respect and stability. The speakers also discuss the importance of reducing fear during times of change, preparing future leaders, and creating environments where people can thrive alongside innovation.If you're curious about the future of leadership, Lean thinking, and how organizations can embrace innovation without losing their focus on people, this episode offers a powerful preview of the ideas and conversations that will take center stage at the Lean Solutions Summit.Key Takeaways:1. Innovation should enhance people—not replace them2. Great leadership requires stewardship, humility, and a commitment to developing others3. Respect, stability, and psychological safety are essential foundations for continuous improvement4. The future belongs to organizations that successfully combine technology, innovation, and human-centered leadershipLinks: Lean Solutions Summit Lean Solutions Website

From Action Plans to Experiments 26.05.2026 34min

What You’ll Learn in This Episode:In this episode, Patrick Adams welcomes back Beth Carrington to explore the difference between simply executing action plans and developing true scientific thinking through Improvement Kata and Coaching Kata.Beth shares her journey from the automotive industry into Lean transformation work and explains how discovering Toyota Kata fundamentally changed her approach to leadership and continuous improvement. The conversation breaks down why organizations often over-rely on rigid action plans and how experimentation creates better long-term learning and adaptability.You’ll learn how leaders can use simple coaching routines, PDCA cycles, and reflection questions to help teams think more scientifically, solve problems more effectively, and stay focused on outcomes rather than just completing tasks. Beth also explains why AI and emerging technologies make experimentation and scientific thinking even more important in today’s business environment.If you’ve ever struggled with teams becoming too task-focused or wondered how to build a stronger culture of learning and experimentation, this episode provides practical tools and frameworks to help you get started.Key Takeaways:Action plans alone can limit learning and adaptabilityScientific thinking is built through experimentation, reflection, and coachingPsychological safety is essential for teams to admit uncertainty and learnAI and emerging technologies increase the need for experimental thinking and continuous learningLinks:Kata Matters WebsiteBeth Carrington LinkedInLean Solutions Summit Lean Solutions Website

The Wheel of Sustainability Explained 19.05.2026 30min

What You’ll Learn in This Episode:In this episode, Andy Olrich sits down with returning guest Adam Lawrence to explore why so many improvement efforts fail to stick and what leaders can do to create lasting, sustainable change.Adam shares the origin story behind his “Wheel of Sustainability” framework and explains why sustainability is ultimately a leadership process, not just a technical one. The conversation dives into the importance of preparation before a Kaizen event, including leadership alignment, clear expectations, strong sponsorship, and creating accountability systems before improvement work even begins.You’ll also learn practical ways to strengthen sustainability after an event through audits, visuals, standard work, Gemba walks, and leadership engagement. Adam and Andy discuss why culture, trust, and respect for people are just as important as financial results—and how the true test of success is when employees start asking, “When can you come help my area next?”If you’ve ever struggled with improvements fading over time or leaders failing to stay engaged after an event, this episode provides a practical roadmap for building improvements that last.Key Takeaways:Sustainable improvement starts with leadership commitment and preparationKaizen events fail when leaders don’t stay visibly engaged before, during, and after the workAudits, visuals, standard work, and accountability systems help improvements stickThe strongest sign of success is when teams ask for more improvement work in their own areasLinks:Adam Lawrence LinkedInPI PartnersThe Wheel of SustainabilityLean Solutions Summit Lean Solutions Website

Unlocking Potential on the Frontline 12.05.2026 34min

What You’ll Learn in This Episode:In this episode, Shayne Daughenbaugh and Catherine McDonald sit down with leadership strategist and Army veteran Jonathan Pride to explore the SOAR mindset. A leadership framework built around storytelling, ownership, abundance, and resilience.Jonathan shares how leaders can move beyond compliance-driven management and develop teams through coaching, curiosity, and intentional conversations. The discussion highlights why storytelling is one of the most overlooked leadership tools and how leaders can use their lived experiences to build trust, connection, and influence.You’ll also learn how practical habits like asking better questions, using the “three whys,” and starting each day with intentional praise can create stronger teams and more empowered problem solvers. The conversation emphasizes that leadership development starts internally through self-awareness, mindset, and personal growth, before it ever impacts others.If you’ve ever wondered how to become a more authentic, resilient, and people-centered leader, this episode offers a practical framework to help you start. Key Takeaways:Great leadership starts with owning your story and lived experiencesCoaching and curiosity develop better problem solvers than control and complianceSmall mindset shifts and micro habits can create meaningful leadership growthIntentional praise helps leaders build resilience, perspective, and an abundance mindsetLinks:Click Here for Jonathan Pride's LinkedInThe SOAR Mindset Website Lean Solutions Summit Lean Solutions Website

Hidden Costs are Killing Margins 05.05.2026 39min

What You’ll Learn in This Episode:In this episode, Patrick Adams, Catherine McDonald, Shayne Daughenbaugh, and Andy Olrich unpack the hidden costs that quietly erode margins, and why most organizations don’t see them coming.You’ll learn how these costs often live outside traditional financial statements, showing up instead as rework, inefficiencies, poor handoffs, and constant interruptions like “hot jobs.” The team shares real-world examples of how these hidden issues build up over time and significantly impact performance.The conversation highlights practical ways to uncover these costs, including going to the gemba, mapping processes, making data visible, and engaging teams through consistent one-on-one conversations. They also emphasize the role of leadership in either allowing waste to continue through workarounds or actively eliminating it by creating clarity, standards, and accountability.If you’ve ever looked at your financials and wondered where the margin is going, this episode gives you a clear and actionable approach to finding and fixing the leaks.Key Takeaways:Hidden costs don’t show up on financials—but they directly impact marginsRework, poor flow, and “hot jobs” are major sources of cost leakageVisibility through data, process mapping, and GEMBA is key to uncovering issuesLeadership behavior determines whether waste is allowed or eliminatedLinks:Lean Summit | FindleansolutionsLean Solutions | Find Your Lean Solution TODAY!

Gemba for Beginners: Why Leaders Need to Go See the Work 28.04.2026 32min

What You’ll Learn in This Episode:In this episode, Patrick Adams and Shayne Daughenbaugh break down the true meaning of GEMBA and why it’s a foundational practice in Lean leadership.You’ll learn how going to the “real place” helps leaders move beyond assumptions and understand what’s actually happening in their processes. The conversation highlights why many leaders avoid the gemba. Often due to fear, ego, or lack of clarity. Also, how shifting to a mindset of curiosity, humility, and vulnerability can change everything.They also explore how to approach GEMBA in both manufacturing and knowledge work environments, emphasizing the importance of building trust, creating psychological safety, and following up on what you hear.If you’ve ever struggled to connect with your team, understand your processes, or drive meaningful improvement, this episode gives you a simple, practical way to start.Key Takeaways:GEMBA is about understanding reality—not relying on assumptionsLeaders should approach the gemba with curiosity, not judgmentTrust is built through consistency, follow-up, and psychological safetyStart small—pick one process, observe, listen, and learn before actingLinks: Lean Solutions SummitLean Solutions Website

Better Behaviors, Better Outcomes: How Leaders Drive Change 21.04.2026 29min

What You’ll Learn in This Episode:In this episode, Patrick Adams sits down with Cindy Darnell to explore how behavioral assessments like DISC can transform leadership, communication, and team performance.You’ll learn how understanding personality styles helps leaders adapt their communication, reduce conflict, and build stronger relationships across teams. Cindy shares practical examples of how small shifts, like adjusting your level of detail or getting straight to the point, can dramatically improve collaboration and outcomes.The conversation also highlights the importance of self-awareness, recognizing strengths over weaknesses, and understanding that behavior is often influenced by unseen factors. Leaders who take the time to understand both themselves and others are better equipped to drive engagement and continuous improvement.If you’ve ever struggled with communication challenges or wondered how to better connect with different personalities on your team, this episode provides a practical and insightful starting point.Key Takeaways:Self-awareness is the foundation of effective leadership and communicationAdapting your communication style improves collaboration and resultsThere is no “right” personality—diverse styles strengthen teamsFocus on strengths, not just weaknesses, to unlock better performanceLinks: Lean Solutions SummitLean Solutions Website Cindy Darnell's LinkedIn

The 10-Minute Improvement 14.04.2026 29min

What You’ll Learn in This Episode:In this episode, Catherine McDonald and Shayne Daughenbaugh explore the power of small, everyday improvements. What they call the “10-minute improvement.”Instead of focusing only on large-scale Lean projects, they break down how organizations can unlock hidden opportunities by addressing small frustrations, workarounds, and communication gaps that often go unnoticed.You’ll learn how to identify these opportunities, uncover root causes, and create a culture where employees feel empowered to take action. The conversation also highlights the critical role of leadership in fostering psychological safety and encouraging reflection, communication, and continuous improvement at every level.If your organization struggles to move beyond big initiatives or overlooks the small issues that slow teams down, this episode offers a simple, practical framework to start making meaningful progress today.Key Takeaways:Small improvements often create the biggest impact over timeWorkarounds hide problems—don’t ignore them, fix themWhat you tolerate becomes your process standardCommunication and psychological safety are essential for continuous improvementLinks:Lean Solutions 2026 SummitLean Solutions Website

Smart Steps in Industry 4.0 (Part 2) 07.04.2026 19min

What You’ll Learn in This Episode:In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent dive into the real starting point of Industry 4.0—shifting from “proof of concept” to “proof of value.”You’ll learn why simply collecting machine data isn’t enough, and how to tie that data directly to financial outcomes that matter to leadership. The conversation breaks down practical first steps like digitizing paper processes, improving network infrastructure, and starting small with one machine or process.They also explore the hidden risks of technology debt, why many manufacturers are sitting on “ticking time bombs,” and how failing to modernize foundational systems can lead to major operational disruptions.If you’ve ever struggled to justify digital investments or felt stuck between old systems and new technology, this episode gives you a clear, practical path forward.Key Takeaways:Proof of value matters more than proof of conceptYou can’t improve what you can’t see—data visibility is criticalStart small, but build a strong digital foundationIgnoring technology debt creates major future riskLinks:Lean Solutions 2026 SummitLean Solutions Websitehttps://realisepotential.com.au/https://www.linkedin.com/in/johnsbroadbent/

Smart Steps in Industry 4.0 (Part 1) 31.03.2026 22min

What You’ll Learn in This Episode:In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent break down what Industry 4.0 really means, and why it’s not as complex or expensive as many think.You’ll learn how to start small, connect existing systems, and use data more effectively to improve operations. The conversation highlights why Industry 4.0 is about integration, not technology, and how even simple steps, like auditing spreadsheets or connecting one machine, can kickstart your transformation.If you’ve ever thought “we’re not ready for Industry 4.0,” this episode will challenge that belief and give you a practical starting point.Key Takeaways:1. Industry 4.0 isn’t about technology, it’s about integration2. Industry 4.0 is a journey, NOT a one-time project3. Visibility is the first step to transformation4. Context matters more than dataLinks:Lean Solutions 2026 SummitLean Solutions Websitehttps://realisepotential.com.au/Email: john@realisepotential.com.au

Stop Selling Lean: Start Solving Problems 24.03.2026 30min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald break down one of the biggest reasons Lean fails in organizations, and how it has nothing to do with the tools.Most companies try to “sell Lean” as a program or initiative, which immediately creates resistance. Employees see it as something being done to them instead of for them. But the real key to success is much simpler: stop selling Lean and start solving real problems that people face every day.The conversation dives into how leadership behaviors shape culture, why small wins matter more than big projects, and how building trust through employee involvement can transform an organization. You’ll also learn why traditional reward systems often backfire, and how to create a continuous improvement system that actually sticks.If your Lean efforts feel stuck—or your team isn’t buying in—this episode will completely change how you approach transformation.Key Takeaways:1. Stop selling Lean—start solving real problems2. Leadership behavior—not tools—determines success3. Small wins build trust faster than big initiatives4. Lean must be a system, not an eventLinks:Lean Solutions 2026 SummitLean Solutions Website

How to Accelerate Your Business Transformation 17.03.2026 31min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Patrick Adams and Shayne Daughenbaugh sit down with Lean expert Darren Walsh to uncover why most Lean transformations stall, and what leaders must do to accelerate real business transformation.With more than 25 years of experience working with world-class organizations, Darren explains why many companies struggle with continuous improvement despite investing heavily in Lean tools like Kaizen and value stream mapping. The problem isn’t the tools; it’s the leadership mindset, flawed improvement strategies, and a focus on efficiency instead of value flow.The conversation explores how daily management systems, visual management, leadership routines, and better problem-solving can dramatically accelerate Lean results. Darren also shares practical strategies leaders can use to ensure teams work on the right problems, remove organizational blockers, and build sustainable continuous improvement habits.If your Lean initiative feels stuck, this episode reveals the leadership shifts needed to unlock faster transformation and lasting operational excellence.Key Takeaways:1. Most Lean transformations fail because leaders focus on efficiency instead of value flow2. Delegating improvement kills continuous improvement3. Daily management is the foundation of Lean success4. Most teams are solving the wrong problemsLinks:Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Darren Walsh's LinkedInhttps://www.makingleanwork.org/

The Future of Lean: Strategy, AI, and People 10.03.2026 31min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, hosts Patrick Adams and Shayne Daughenbaugh are joined by Marco Dannerhill to explore how Lean thinking must evolve in today’s fast-changing business environment. Drawing on more than three decades of experience in the plastics industry, Marco shares how Lean has shifted from focusing on localized process improvements to becoming a more strategic approach that supports long-term business success.The conversation dives into how global uncertainty, supply chain disruption, and emerging technologies like AI are changing the way organizations operate. Marco emphasizes that while technology can enhance productivity, people remain the heart of Lean, and leadership must prioritize coaching, mentoring, and building trust across teams. The discussion also highlights the importance of aligning improvement initiatives with strategic goals, empowering employees to lead smaller improvements, and ensuring that Lean efforts contribute to long-term growth rather than just short-term gains.Key Takeaways:Lean must evolve from local improvements to strategic impactTechnology should support people, not replace themLeaders must coach and mentor to build a culture of improvementStrategy must be translated so frontline teams understand their roleLinks: Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Marco Dannerhill's LinkedIn

Making Lean Stick: It Starts with Leadership 03.03.2026 25min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, hosts Patrick Adams, Andy Olrich, and guest Steve Riley discuss the importance of leadership behaviors in maintaining Lean initiatives. They highlight how unintentional actions, such as not picking up trash or not following standard work, can undermine Lean efforts. Steve Riley, a manufacturing operations leader with over 30 years of experience, emphasizes the need for consistent leadership presence, protecting standards under pressure, and fostering team-led improvements. They also explore the significance of measuring both leading and lagging indicators to ensure continuous improvement. Additionally, Riley introduces his company's digital shadow board service, which simplifies the creation of tool organization systems.Key Takeaways:Leadership behavior matters more than Lean toolsWhat leaders do in the moment defines credibilityLean breaks when standards are optionalImprovement must be part of daily workLinks:Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Steve Riley's LinkedInbespoketooltrays@gmail.comTool Box Foam, 5S Lean, 5 S Lean | BespokeToolTrays.com

The First 90 Days of Lean: What Actually Matters (Part 2) 24.02.2026 16min

What You’ll Learn in This Episode:In this second part episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh discuss the initial steps for a new leader implementing Lean principles. They emphasize understanding the current state through one-on-one interviews and Jeff Liker's leadership development model, which includes personal development, coaching others, daily Kaizen, and establishing a vision. Patrick advises starting with a model area to experiment with Lean concepts on a smaller scale. Shayne shares his experience of finding a champion and creating a safe space for experimentation. They both stress the importance of learning from failures, building team capability, and gradually introducing Lean practices to achieve organizational goals.Key Takeaways:Start Lean by Understanding the Current State—Not by Teaching ToolsYour First 90 Days Should Focus on Leadership Development, Not ControlCreate a “Sandbox” or Model Area to Learn Fast and SafelyFailure Is a Win When Learning Is the GoalLinks:Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠⁠

The First 90 Days of Lean: What Actually Matters (Part 1) 17.02.2026 15min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh explore what the first 90 days should look like after discovering Lean or stepping into a new organization. Once someone understands the principles of continuous improvement, what should they actually do first? They discuss how your approach must shift depending on your level of influence. Whether you’re an executive, middle manager, or individual contributor, rushing into tools and events can create resistance instead of momentum.They advise spending time in direct reports' roles, having one-on-one conversations, and documenting feedback to identify common issues and improve processes. They also highlight the value of using emotions as flags and leveraging AI to analyze data for better decision-making. They agree on the importance of empathy and trust-building in leadership.Key TakeawaysYour Role Determines Your StrategyStart with Listening, Not ImplementingCulture Before ToolsPerspective Changes EverythingLinks: Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠⁠

Going from Strategy to Starting 10.02.2026 29min

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald explore what happens after the strategy day is over. Once goals are set, how do organizations move from planning to real execution? They highlight the challenges of managing too many goals and the necessity of engaging teams in the strategy process. They unpack why teams often struggle—not because they lack ideas—but because they have too many priorities and not enough clarity on where to start. The discussion focuses on practical frameworks for filtering, prioritizing, and executing goals in a way that aligns strategy with daily work.Key Takeaways:Teams don’t struggle from a lack of ideas—they struggle from too many priorities.Don’t start where it’s exciting—start where it’s expensive.Use structure to remove subjectivity.Links: Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Catherine McDonald’s LinkedIn⁠⁠⁠⁠Click Here For Andy Olrich’s LinkedIn⁠⁠

Opportunities to Coach at Work 03.02.2026 32min

What You’ll Learn in This EpisodeIn this episode, hosts Catherine McDonald and Shayne Daughenbaugh discuss what coaching in the workplace really means. Why it’s far more than a buzzword. The conversation breaks down the difference between coaching, training, and mentoring, and explains how coaching serves as a powerful leadership approach for developing people, building trust, and sustaining continuous improvement.They emphasize how coaching shows up in day-to-day work through huddles, Gemba walks, and one-on-ones, and how lean tools like PDCA naturally support a coaching mindset. Key TakeawaysCoaching is a leadership approach, not an event.Coaching is different from training and mentoring.Every day work creates coaching opportunities.LinksLean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠Click Here For Catherine McDonald’s LinkedIn⁠⁠

Why the Best Leaders Ask Better Questions: Part 2 27.01.2026 16min

What You’ll Learn: The second half dives deeper into the people side of continuous improvement. Dave explains how Nemawashi and intentional conversations help build alignment, trust, and momentum. Listeners learn why asking thoughtful questions—like “who else should we talk to?”—can naturally expand buy-in and lead to better decisions. The episode wraps with reflections on leadership, learning, and staying connected within the Lean community.Key Takeaways:How Nemawashi helps build buy-in naturallyWhy asking “who else should we talk to?” strengthens decisions and alignmentHuman, Pet, and Animal Nutrition Company: WebsiteClick Here for Dave Kippen's LinkedInLean Solutions Website

Why the Best Leaders Ask Better Questions 20.01.2026 13min

What You'll Learn: In the first half of the episode, the conversation focuses on the foundations of effective change and project success. Dave shares insights on the importance of executive support, strong project management, and understanding the real problems teams are trying to solve. The discussion highlights why improvement efforts often stall and how leaders can create clarity by engaging the right stakeholders early.Key Takeaways:Why executive support can make or break improvement effortsHow a clear problem definition sets the foundation for successLinks: Click Here for Dave Kippen's LinkedInHuman, Pet, and Animal Nutrition Company: WebsiteLean Solutions Website