The Lean Solutions Podcast

Afleveringen

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  People + Innovation: A Pre-Summit Series 04.08.2026 35min

  What You'll Learn in This Episode:In this episode, Patrick Adams is joined by Paul Doyle and Shawna Hondorp for a preview of their sessions at the Lean Solutions Summit. Together, they explore two critical topics shaping today's organizations: developing leaders through intentional systems and using AI to strengthen talent acquisition without losing the human connection.The conversation dives into why leadership development should be treated as a business process rather than a training program, how specific leadership behaviors can be standardized and developed across every level of an organization, and why AI works best when paired with a thoughtful strategy. Shawna also shares practical insights into using AI responsibly in recruiting, emphasizing transparency, compliance, and the importance of maintaining authentic human relationships throughout the hiring process.Whether you're leading a team, developing future leaders, building an AI strategy, or improving your hiring process, this episode provides practical insights for creating stronger leaders, smarter systems, and more intentional organizations.Key Takeaways:Leadership development is a business process—not just a training programStrong leadership is built through intentional behaviors and systemsAI should enhance human connection, not replace itA successful AI strategy requires intentionality, transparency, and trustLinks: https://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  How to Find the Real Root Cause 28.07.2026 33min

  What You'll Learn in This Episode:In this episode, Shayne Daughenbaugh sits down with Seamus Maguire to explore one of the biggest reasons problem-solving fails, even in organizations with experienced people and proven Lean tools. Drawing from his new book, Finding Fact Before Fixing, Seamus explains how cognitive biases, assumptions, and the pressure to find quick answers often lead teams to solve the wrong problem.The conversation explores why hypothesis testing and experimentation should be at the center of every problem-solving effort, how leaders can ask better questions to uncover true root causes, and why collecting the right data is more important than simply collecting more data. Seamus also shares practical ways to challenge assumptions, use the scientific method in everyday problem-solving, and create a culture where teams focus on finding facts before implementing fixes. Key Takeaways:Challenge assumptions before finding solutionsUse hypothesis testing instead of educated guessesAsk better questions to uncover root causesCollect the right data—not just more dataLinks:linkedin.com/in/seamusmaguire?utm_source=share_via&utm_content=profile&utm_medium=member_ioshttps://www.routledge.com/Finding-Fact-Before-Fixing-How-Business-Professionals-Can-Avoid-False-Assumptions-When-Solving-Problems/Maguire/p/book/9781041130307https://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  People + Innovation: A Pre-Summit Series 21.07.2026 38min

  What You'll Learn in This Episode:In this episode, Patrick Adams is joined by Brett Lesiewicz, Judd VanBergen, and Phil Ranck for a preview of their sessions at the 2026 Lean Solutions Summit. Together, they explore how stronger relationships, proactive planning, and better communication help organizations succeed in uncertain environments.The conversation highlights how Lean tools like the Last Planner System, takt planning, and visual management are transforming the construction industry by creating alignment, improving collaboration, and reducing uncertainty before work even begins. Phil also introduces the Seven Thinking Gears, a structured communication framework designed to make meetings more productive, uncover innovative ideas, and empower every team member to contribute to continuous improvement.Whether you're in construction, manufacturing, healthcare, or another industry, this episode offers practical insights into building stronger teams, improving communication, and creating more predictable results through Lean thinking.Key Takeaways:1. Strong relationships create certainty in uncertain environments2. Proactive planning prevents costly rework3. Better communication unlocks innovation4. Lean principles apply far beyond manufacturingLinks: https://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  Lead With Your Eyes 14.07.2026 32min

  What You'll Learn in This Episode:In this episode, Andy Olrich and Catherine McDonald sit down with Andrew Kettner to discuss why one of the most overlooked leadership skills, eye contact, can have a profound impact on trust, communication, and continuous improvement.Andrew explains how effective leaders must look beyond reports, dashboards, and data by practicing Lean's "go and see" mindset. Through genuine face-to-face interactions, leaders gain valuable insights into emotions, engagement, and the real challenges their teams face. The conversation also explores the connection between eye contact, empathy, emotional intelligence, and building stronger workplace relationships. Andrew shares personal stories from his military leadership experience and cancer journey that demonstrate how meaningful human connections can influence both leadership and life.Whether you're leading a Lean transformation or simply looking to become a more effective leader, this episode offers practical ways to strengthen your leadership presence by learning to truly see the people you lead.Key Takeaways:Great leaders practice "go and see" by engaging directly with people—not just data.Eye contact builds trust, empathy, and stronger workplace relationships.Emotional intelligence helps leaders better understand both people and processes.Small, intentional interactions create stronger Lean cultures and better leadership.Links:https://www.linkedin.com/in/andrewkettnerhttps://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  People + Innovation: A Pre-Summit Series 07.07.2026 32min

  What You'll Learn in This Episode:In this episode, Patrick Adams sits down with John Dyer to explore the thinking behind the Lean Excellence World Championship and why it has become one of the most engaging learning experiences at the Lean Solutions Summit.The conversation dives into how the competition gives participants and observers the opportunity to see Lean in action. From process mapping and visual management to problem-solving, teamwork, and customer focus. John explains why process mapping is the foundation of every successful improvement effort, how it helps teams visualize workflows, uncover hidden waste, identify bottlenecks before implementation, and create stronger future-state processes. He also shares why every organization, regardless of industry, can benefit from making process mapping a core part of its continuous improvement strategy.Whether you're new to Lean or looking to strengthen your continuous improvement efforts, this episode provides practical insights into learning Lean through hands-on experience and applying process mapping to improve any process.Key Takeaways:1. Process mapping is the foundation of improvement2. Lean is learned best through hands-on experience3. Customer focus drives better decisions4. Great Lean cultures embrace problemsLinks:https://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  Leading with MORE 30.06.2026 30min

  What You'll Learn in This Episode:In this episode of the Lean Solutions Podcast, Catherine McDonald sits down with Kathy Miller to explore why successful transformations are driven by people, not just processes.You'll learn how trust, meaningful work, optimism, and strong relationships create lasting cultural change, why consistency is essential for leaders, and how simple daily leadership habits can increase engagement and continuous improvement across any organization.Whether you're leading a Lean transformation, managing a manufacturing team, or looking to build a stronger workplace culture, this episode offers practical insights for creating lasting change through people-first leadership.Key Takeaways:1. Great transformations begin with trust2. People need purpose—not just processes3. Culture changes through consistent leadership4. Positive psychology strengthens LeanLinks:https://more4leaders.com/linkedin.com/in/kathy-miller-mapp-mba-acchttps://www.findleansolutions.com/https://www.findleansolutions.com/lean-summit/
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  SIPOC: start improvement right 23.06.2026 32min

  What You'll Learn in This Episode:In this episode, Catherine McDonald and Shayne Daughenbaugh welcome Michael Parent to discuss SIPOC, one of the most effective tools for understanding and improving business processes. Michael explains how SIPOC (Suppliers, Inputs, Process, Outputs, Customers) helps teams define process boundaries, identify stakeholders, and maintain focus on delivering customer value.The conversation explores different approaches to building a SIPOC, including why Michael prefers starting with the customer before mapping the process itself. They also discuss how SIPOC fits into Lean and Six Sigma problem-solving, how it helps prevent scope creep, and why it serves as a strong foundation for process mapping, stakeholder engagement, and continuous improvement efforts.Whether you're leading a process improvement project or trying to better understand how work flows through your organization, this episode provides practical guidance on using SIPOC to create clarity and alignment from the start.Key Takeaways:1. SIPOC provides a high-level view of a process and helps clearly define project scope and boundaries.2. Keeping the customer at the center of the discussion ensures improvement efforts remain focused on delivering value.3. SIPOC serves as a powerful starting point for process mapping, stakeholder analysis, and continuous improvement initiatives.4. The most effective SIPOCs involve the right mix of stakeholders and subject matter experts while avoiding unnecessary complexity and scope creep.Links:mparent@sixsigma-consulting.comhttps://www.linkedin.com/in/parent-michael/https://www.findleansolutions.com/summit-2026/https://www.findleansolutions.com/
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  The First 90 Days of Lean: What Actually Matters (Part 1) 16.06.2026 15min

  What You’ll Learn in This Episode:Spotlight Episode!!As we continue revisiting some of the conversations that sparked meaningful discussions, we’re bringing back this episode of the Lean Solutions Podcast with Patrick Adams and Shayne Daughenbaugh.In this conversation, Patrick and Shayne explore what new leaders should focus on when stepping into a Lean journey. Instead of jumping straight into tools and solutions, they discuss the importance of understanding the current state, building relationships, developing people, and creating the right environment for improvement.From creating a model area for experimentation to learning through failure, this episode highlights why successful Lean transformation starts with leadership, trust, and capability building.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
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  SOPs That Don't Collect Dust 09.06.2026 30min

  What You'll Learn in This Episode:In this episode, Catherine McDonald and Shayne Daughenbaugh discuss the practical realities of capturing, creating, and deploying Standard Operating Procedures (SOPs) in fast-growing organizations. Drawing from Shayne’s experience leading SOP standardization across multiple locations, they explore how businesses can create consistency while maintaining a human-centered approach.The conversation highlights why SOPs are more than compliance documents. They serve as the foundation for customer experience, employee training, and continuous improvement. Shayne shares a step-by-step framework for identifying priority processes, working with subject matter experts, and leveraging video recordings and AI tools to simplify documentation and accelerate SOP creation.If your organization struggles with inconsistent processes, scattered documentation, or SOPs that nobody uses, this episode offers practical strategies for building documentation that is both useful and sustainable.Key Takeaways:1. SOPs should create consistency across locations to deliver a reliable customer experience.2. Video-based process capture preserves valuable expertise, context, and real-world best practices better than traditional written documentation.3. AI and transcription tools can significantly speed up SOP creation while reducing administrative effort.4. SOPs are most effective when treated as living documents that support continuous improvement, not just compliance or record-keeping.Links: Lean Solutions Summit Lean Solutions Website
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  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
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  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
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  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
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  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 
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  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!
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  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 
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  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
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  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
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  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/
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  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
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  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