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Explore every episode of the podcast Lean Six Sigma Bursts

Dive into the complete episode list for Lean Six Sigma Bursts. Each episode is cataloged with detailed descriptions, making it easy to find and explore specific topics. Keep track of all episodes from your favorite podcast and never miss a moment of insightful content.

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1–50 of 140

TitlePub. DateDuration
E106: The Lean Journey at Rockwell Collins with Clay Jones - Part 329 Jun 202400:11:55

This is part 3 of the 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program.


In this clip, you'll hear him discuss why they brought in some external consultants like John Shook and Denny Mead to try and figure out why all the improvements were not showing an impact on the bottom-line results or other key metrics. The RC Scorecard was developed to give a balanced view across the company, and it included a critical metric, called Cost of Nonconformance (CONC), which I was heavily involved with. He also discusses how leadership needed to become more engaged in value stream mapping to help drive the right improvements in the right areas by following the new "Lean Roadmap."


You can watch the entire video at ⁠⁠http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation⁠⁠

If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: ⁠⁠⁠⁠https://www.leansixsigmadefinition.com/shop/⁠⁠⁠⁠

E105: The Lean Journey at Rockwell Collins with Clay Jones - Part 224 Jun 202400:12:17

This is part 2 of the 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program.


In this clip, you'll hear him discuss how they created and rolled out Lean Electronics program across both manufacturing and the office, and selected Decorah (Iowa) as the pilot site. In the first few years (1998-2000), they achieved lots of successes (conducting over 600 kaizen events a year with reductions of 20-40%), but something was missing.


Enterprise Value Stream Mapping was added through an initiative called Core Process Optimization (CPO) to look at major pieces of the customer journey, from Sales and Marketing, Design and Development, Build (Manufacturing) and Sales and Support.


You can watch the entire video at ⁠http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation⁠

If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: ⁠⁠⁠https://www.leansixsigmadefinition.com/shop/⁠⁠⁠


E96: What is the best option for effective Lean Six Sigma training and coaching?02 Feb 202400:12:20

When I talk to clients about training their team, that usually opens up a lot of questions in my mind that we'll need to discuss before I can give them a ballpark number quote.

In this podcast, I run through the questions you need to consider in order to create an effective training program that will result in hands-on application and payback on the investment, while keeping the costs minimal.

If you'd like to get a quote for some training options, fill out this training request form, and we'll be in touch, or contact me at ⁠⁠brion@biz-pi.com⁠⁠


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E6: What are Pareto charts and why should you display them horizontally?30 Aug 202000:03:56

I explain what Pareto charts are, and why they should be used more often than they are. I also summarize an older article I wrote about changing the way to display these charts.

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E5: What are hypothesis tests and why do we need them?28 Aug 202000:04:43

I explain how and when hypothesis tests can be used, based on a recent article I wrote, which looked at the racial inequities brought up by football players at the University of Iowa and the data that can support these claims.

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E4: What is the DMAIC Improvement model?23 Aug 202000:02:11

I created a video that accompanies this quick explanation of DMAIC, which stands for Define, Measure, Analyze, Improve and Control. DMAIC is the core structure used in Six Sigma projects

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E3: What is the Influencer model and how it applies to wearing masks?23 Aug 202000:04:46

In this episode, I discuss the Influencer behavior change model, and how it applies to getting people to wear their masks to prevent the spread of COVID-19

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E2: What is the difference between hard and soft financial savings?23 Aug 202000:04:07

In this episode, I answer a question I often receive about how to categorize financial cost savings from improvement, either hard or soft, and what is the difference?

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E1: Why are Six Sigma Black Belts paid so much?23 Aug 202000:04:53

In this first episode, I answer a question I received about salaries for Six Sigma Black Belts, and why I think they make good money.

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Lean Six Sigma Bursts (Trailer)22 Aug 202000:00:40
E95: Hypothesis Testing Basics - Can James Bond tell the difference between a shaken or stirred martini?23 Jan 202400:04:37

To explain the concepts of hypothesis testing (null and alternative hypothesis statements), I use an example of James Bond. His famous line is "shaken, not stirred" when ordering a martini.


In a hypothesis test, we would set the null (default) hypothesis to say that he cannot tell the difference. The alternative hypothesis would be proven if there was data showing he could tell the difference (better than guessing or chance).


Hope this helps you understand the concept of hypothesis testing a little more clearly.


Are you interested? Contact me at ⁠brion@biz-pi.com⁠


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E94: Interested in a Free "Lean at Home" Coaching Program?08 Jan 202400:03:39

Back in 2020, I created a course called "Home Efficiency Using Japanese Lean Productivity Techniques" and I'm offering a free coaching program this month to help you complete the course and get help implementing the concepts into your personal life.


Are you interested? Contact me at brion@biz-pi.com


Links

Podcast episodes #50-56 (Audio version of course)


E93: An overview of Statistical Process Control (SPC)11 Dec 202300:06:49

In one of my recent Six Sigma classes, I provide a simplistic explanation of SPC and control charts, and why they are essential to detecting problems quickly in your processes.


If you're interested in learning more about SPC, check out the link below.


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E92: Should my kaizen event be a planning session or a working session?04 Dec 202300:08:16

In one of my recent Lean classes, I discuss the difference between planning kaizen events and working kaizen events. Planning events end up with a 90-day implemenatation plan. Working events end up with 80% completion of actions by the end of the event, with 30 days to complete the remaining 20% of the actions. I try and encourage more working sessions, but planning is sometimes really important to decide where to focus the working sessions in the future.


To better understand this podcast, watch the State of Washington VSM video (about 10 minutes).


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E91: How can I get the most frontline worker participation in a kaizen working event?27 Nov 202300:06:23

In one of my recent Lean classes, I discuss ways to engage front line workers in working kaizen events. I talk about the differences between working and planning sessions in my last podcast. I discuss options for working ahead, catching up afterwards, having half-day sessions (half kaizen, half working), splitting the event across many shifts, and having the leads and supervisors participate but checking in with the workers frequently.

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E90: Free Lean and Sustainability Webinar Series - Nov 28th and 30th18 Nov 202300:07:05

I've been helping set up a webinar series with support from the Iowa Sustainable Business Forum and the Iowa Lean Consortium. There are two webinars you can choose from, or sign up for both.


I will be presenting the first webinar, Lean Methods for Sustainable Organizations. I will introduce those in sustainability roles to Lean methods, which have become some of the most popular improvement methods used in high-performing organizations in manufacturing, healthcare, government and many other industries.


The second webinar, Sustainability for Lean Organizations, will be presented by Adam Hammes from SGS North America. He will help demonstrate to process improvement specialists, engineers, and management the business case for applying risk and quality management strategies like Lean to sustainability performance.


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E89: Q&A from Six Sigma training - What to do when data collection system is under development?12 Nov 202300:05:11

In this episode, I answer another question in one of my Six Sigma classes. The student said they were having supplier issues, but the data wasn't very good. There is a plan to implement a data collection system, but it might not be ready for a few months. Should she wait until the system is ready and then start her project, or start now and collect the data manually.


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E88: Q&A from Six Sigma training - What if solutions are part of your Six Sigma project charter?05 Nov 202300:07:45

In this episode, I answer a question in one of my Six Sigma classes. The student said they were not sure if their project could be used, because it alreadys mentions some solutions to the problem, and the training said no solutions can be defined at the beginning of a Six Sigma project. He wanted to know how to handle this situation, which is very common.


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E87: Six Sigma in Real Life: Taguchi Loss Function for Hotel Pool Temps and the Solar Eclipse31 Oct 202300:09:37

In this podcast, I discuss the Taguchi Loss Function again, this time using some real-life examples. I discuss hotel pool temperatures, solar eclipses, and fruit ripeness.


I originally talked about this topic in Episode 37, explaining how an increase in variation away from the target value (even within specification limits) leads to an exponential increase in customer dissatisfaction. This is different than the traditional approach of viewing results within the specification limits as good, and results outside of the specification limits as bad.


Hope you enjoy this topic. If you think of other real-life examples, please let me know!

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E104: The Lean Journey at Rockwell Collins with Clay Jones - Part 118 May 202400:08:32

For the next few podcasts, I'll be sharing clips from a 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program. I credit Clay and the "Lean Electronics" program for giving me the skills and experience to make this my passion, allowing me to eventually open up my consulting business, BPI.


In this video, you'll hear him discuss how he first learned about Lean from Boeing, and what the customers were telling him about their products and services and what needed to improve.


You can watch the entire video at http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation

If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: ⁠⁠https://www.leansixsigmadefinition.com/shop/⁠⁠

E86: Camping and the 8 Wastes (TIM WOODS)12 Oct 202300:20:57

In this episode, I go through TIM WOODS, which is an acronym to describe the 8 types of waste in a process. As an example, I discuss how the 8 wastes apply to recent camping trips I've been making with my wife this summer and fall. Hopefully, this gives you some ideas on how to see waste in your daily activities and work tasks.

Sorry for the length of this podcast, I guess I had a lot to talk about!


Links

E85: Six Sigma Criticisms #1 - The Motorola 1.5 Sigma Shift02 Oct 202300:09:36

In this episode, I discuss some common criticisms about Six Sigma that I've been hearing about over the years. These tend to make their rounds on LinkedIn every few months or years, so I wanted to take each one and go much deeper in the podcast than I can online.

Let's start with one of the biggest ones, the 1.5 sigma shift, also called the Motorola Shift.

If there are others you have heard about you'd like me to discuss, contact me and I'll add it to a future episode.


Links

E84: Using Process Mapping and Regression to Reduce Electricity Usage13 Sep 202300:13:06

In this episode, I discuss my work with a client that is trying to improve their sustainability score. One of the next steps is to establish a goal for electricity reduction, since it is a large contributor to their carbon footprint. I explain how to apply process mapping to heating and cooling a building, and why regression modeling and analysis can be helpful in focusing your electricity reduction efforts.

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E83: Clip from Interview with Climate Change Professional David Saunders26 Aug 202300:06:44

In this episode, I discuss an interview and discussion I had with Climate Change Professional and former Quality executive, David Saunders. We talk about how to leverage your skills of process and quality improvement to improve the environment and help mitigate climate change.

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E82: Q&A from SPC presentation - What software to use? What about nonnormal data?16 Aug 202300:07:34

In this episode, I share some audio from a presentation I gave to Lean Portland for their July Happy Hour. I discussed Statistical Process Control (SPC) and how to detect out of control conditions. I'm sharing two questions that were asked at the end of the talk:

1) For office applications of SPC, what software package would be recommended to make control charts?

2) What control chart do you use if your data is nonnormal?

The full presentation can be watched at the link below.

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E81: Does Toyota use SPC Control Charts?08 Aug 202300:08:49

In this episode, I share the audio from a presentation I gave to Lean Portland for their July Happy Hour. I discuss Statistical Process Control (SPC) and why it's not seen very much in Toyota facilities anymore. I also include a question that was asked related to the transition from monitoring outputs to inputs. The full presentation can be watched at the link below.

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E80: Reduce environmental impacts in your business with Ecology's Lean/Green program10 Jul 202300:08:48

In this episode, I discuss the Washington State Department of Ecology Lean and Green program that I've been supporting the last few years as a consultant. The audio is an interview with the program administrator and my contact point at Ecology, Hugh O'Neill. He shares how this program can help businesses save money, reduce their environmental impact and engage employees. If you are a business in Washington that might be interested, check out the links below. If you're outside of Washington, contact me to learn how we can help you with a customized program. I also invite you to check out my other podcast, "Lean Six Sigma for Good" if you're interested in environmental and societal improvements.

p.s. Hugh is retiring this year, and I'd like to personally thank him for all his work on this topic, and including me in their very important work. You will be missed!

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E79: How to measure variation using Range and Standard Deviation21 Jun 202300:05:57

In this episode, I discuss how to measure variation in a process, using Range and Standard Deviation. Variation is an important concept to understand how to improve a process. This was audio from a recent Six Sigma Yellow Belt course I taught. You might have heard of these concepts before, but hopefully it will be a good refresher for you.

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E78: How to measure central tendency using the mean and median (and which is better)09 Jun 202300:09:43

The following topic was taken from one of my recent Yellow Belt courses, explaining how to use Mean (or average) and Median to measure the middle of a set of data, whether it is solar panel production, calories eaten per day or electricity consumed per day.

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E77: Client Survey Shows Daily Huddles Improve Communication and Engagement Based on Paired T-Test Analysis03 Jun 202300:08:48

For one of my clients, we conducted a survey of their employees to understand if daily huddles were helping them be more engaged in their work. The results of the 7 questions found a statistically significant improvement in scores after the huddles were implemented. Listen to the episode to learn more about the questions and the Paired T-test analysis.

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E103: How to gather data before starting an improvement project05 May 202400:07:01

In a recent class I taught, we were discussing the Project Charter, which asks you to fill in the baseline data for the metric you're trying to improve.

I explain how you need to be persistent to find data, and not to start a project if you don't have any data, especially for a training class, or for your first project.

I also answer a student question about how many samples you need for the baseline. You can also listen to a previous podcast (episode #25) about why we need 30 data points: https://spotifyanchor-web.app.link/e/VAoKfXBelJb


If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: ⁠https://www.leansixsigmadefinition.com/shop/⁠

E76: Why You Should Not Skip Over Measure and Analyze in your DMAIC Improvement Project28 May 202300:04:26

In this episode, I share some audio about DMAIC from a recent class I taught, and I thought you'd find it helpful. I express the importance of ignoring improvement ideas in a DMAIC project until after you go through Define, Measure and Analyze first. You will get pressure to jump to Improve before you're ready, so resist that urge and trust the process.

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E75: Lean in Real Life - Small improvements add up with water cooler and dealing with small samples24 Apr 202300:11:24

In this episode, I discuss an improvement I made at home, that saved time in my personal life, and why small improvements are worth pursuing and not overlooking. I also discuss how small sample sizes are not a barrier to running statistical tests of significance or hypothesis tests.

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E74: 10 things to consider before completing the DMAIC Control Phase05 Apr 202300:08:43

In this episode, I discuss the importance of the Control phase in a Six Sigma DMAIC Improvement project, including the key considerations to make before closing out your improvement activity.

  1. Create a system and/or process to monitor the results
  2. Update any documentation of the processes and procedures
  3. Update any training of the processes
  4. Create a response or mitigation plan in case there is a drop in performance
  5. Add any visual controls or job aids that can be posted in the work area
  6. Review incentives to encourage new improvements to be used or followed
  7. Identify contact names and resources if employee has questions about the new improvements
  8. Schedule process audits or reviews for the next 30, 60 and 90 days
  9. Ensure improvements have been labeled, have a clear storage space, and have someone assigned to reorder them or perform maintenance on them (if applicable)?
  10. Ensure clear ownership of the improvements have taken place by the process owners


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E73: Women in Manufacturing Panel Discussion on Lean Manufacturing24 Feb 202300:10:13

In this episode, I share the audio from a panel discussion I was asked to participate on Wednesday this week. The discussion was focused on Lean Manufacturing, but we also discussed Six Sigma quite a bit. The event was hosted by the Texas Chapter of the Women in Manufacturing Association. They are the only national and global trade association dedicated to providing year-round support to women who have chosen a career in the manufacturing industry

I'm sharing only the segments when I talked, but I encourage you to listen or watch the entire hour-long discussion. The other panelists were Crystal Davis, Dave Crysler, RaeJean Griffin, Sneha Kumari, and Troy Weier.

I have a link to the association and the recording is in the links section below.

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E72: How to finalize a project when results might take years to measure?18 Feb 202300:09:19

In this episode, I provide some tips on how to close out a project or improvement effort, when the primary metric may longer than a year before you might be able to see tangible results. I also discuss other things you can do to prove in the short term that your improvements will be effective in the long run.

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E71: New book release, Lean Six Sigma for Good (Volume 2)28 Jan 202300:05:18

In this episode, I discuss a project I'm really excited about, the 2nd book release in the Lean Six Sigma for Good book series.

This is the 2nd collection of real-life experiences and stories from Lean and Six Sigma practitioners who have spent time at the "gemba" with not-for-profit organizations. They have generously offered to write a chapter about lessons learned and tools they have applied. There are 8 chapters in total.

  • Joe Wojniak and Lynn McCullough: Improving Thrift Shop Donations (interview with authors) - Proceeds donated to TRU Community Care
  • Tim Turner: Helping Others By Following The Toyota Way (podcast interview with Tim) - Proceeds donated to Center for Quality People and Organizations (CQPO)
  • Douglas Cooper: Lessons from Liberia – Standard Work as the Foundation for Lean Practices - Proceeds donated to Mercy Corps
  • Anita Havemann: Reducing Time and Complexity in Nonprofit Accounting - Proceeds donated to Relay Resources
  • Steve Bell: Simple Framework for Complex Problems - Proceeds donated to Lean4NGO.org
  • lisabeth Swan: Leaning into the Mission of Childcare (podcast interview with Elisabeth) - Proceeds donated to Cape Cod Children’s Place
  • Tracy O’Rourke: Increasing Meals Per Hour with Kitchens for Good (podcast interview with Tracy) - Proceeds donated to Kitchens for Good
  • Joy E. Mason: Using Six Sigma to Address Racial Equity (podcast interview with Joy) - Proceeds donated to The Six Sigma Racial Equity Institute

I think this is a great book to share with potential volunteers, or nonprofits or public service agencies wanting to learn more about how Lean or Six Sigma can be applied to their organizations.

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E70: Use ECRS or SPACER to help brainstorm improvement solutions14 Jan 202300:08:54

In this episode, I discuss two acronyms to help you remember ideas on how you can improve a process.

ECRS stands for Eliminate, Combine, Rearrange, and Simplify.

SPACER stands for Standardize, Parallel processing, Automate, Consolidate, Eliminate and Re-arrange.

I also mention SCAMPER, which is similar to these, and stands for Substitute, Combine, Adapt, Modify, Purpose, Eliminate and Reverse.

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E69: Use Action Priority in your next FMEA instead of only using RPN15 Dec 202200:06:05

In this episode, I discuss Action Priority (AP), a newer method for determining which risks from an FMEA should be addressed. Traditionally, the multiplication of Severity, Occurrence and Detection was used to calculate a Risk Priority Number (RPN). Any number over a certain RPN threshold required action to reduce the risk.  Action Priority gives three possible outcome for each risk identified: Low, Medium and High, which can make it easier to decide which RPN scores are more important than others. I also discuss the troubles I've had using a RPN threshold with FMEA teams, as they tend to score just below the threshold intentionally.

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E68: Lean Six Sigma Virtual Coaching and Certification Program Starting in 202306 Dec 202200:10:16

In this episode, I explain a new virtual coaching program I'm launching in January of 2023. 

If you or your team would be interested in completing some online Lean or Six Sigma training, completing a kaizen event or a Six Sigma project, and obtaining a certification, I have three approaches that might work for you at different price points:

  1. Do It With Me (Coaching) – We work closely with you to keep you on track with the training, and we help you with your Six Sigma project or Lean event over a 4-month period. Best combination of self-learning and mentoring.
  2. Do It Yourself (DIY) – You complete the training and project/event primarily by yourself, with a few hours of our support. Lowest cost option but requires self-discipline.
  3. Do It For Me (Consulting) – We take the lead on your Six Sigma project or Lean event, and coach/mentor you as needed, with focus on getting tangible results as quickly as possible. Most expensive but effective option.

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E67: Why Single-stall Production Systems are more efficient than Assembly Lines15 Oct 202200:07:33

In this episode, I explain what a "single-stall production system" means, and why it is superior to the traditional single piece flow assembly line.

Single-stall is a method of work where one highly skilled worker is trained to perform all steps of the process by themselves (often in one stall to reduce floor space), instead of handing off the work to multiple workers in an assembly line.

It can take months or years to develop their skills so they can perform each step at high quality, but it can be the most efficient way to complete a process from beginning to completion.

I share a link to an article I wrote below, and in the episode I explain the videos in the article that better explain the difference between single-stalls and assembly lines.

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E102: How Green Belt training can benefit you personally and your organization25 Apr 202400:05:07

In this podcast, I share a short clip from a recent training class, explaining the benefits of Lean Six Sigma Green Belt training to an organization, but more importantly, why it's important to the people attending the clas personally.


If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/


E66: 16 Surprising But Powerful Concepts I've Learned About Lean11 Oct 202200:14:07

In this episode, I read off an article I just wrote, based on my 20+ years of teaching Lean concepts and principles. These are the topics that get the most attention, solicit the most questions, or are the most eye-opening for my students and clients. 

I also announce the launch of a new Lean course I helped create, called Lean Fundamentals.

You can access the FREE Lean Introduction course (first 5 modules) using coupon code "KICKSTARTLEAN-LSSE"

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Links from article

E65: Lean Case Studies Across Different Industries - Manufacturing, Government and Healthcare23 Sep 202200:05:28

In this episode, I share the audio from a recent video I created. The short video highlights four different industry case studies applying Lean principles and concepts.

The 4 organizations highlighted in the video:

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E64: Applying Lean Thinking and Process Improvement to Nonprofits and NGOs Case Studies17 Sep 202200:07:33

In this episode, I share the audio from a recent video I created. The short video highlights four different examples of nonprofits and NGOs applying Lean principles and concepts to social challenges in the local community.

I also announce our new Lean courses: Lean Introduction and Lean Fundamentals. The Lean Introduction course can be accessed for free using coupon code "KICKSTARTLEAN-LSSE"

The 4 nonprofits highlighted in the video:

Links

E63: Six Sigma in Real Life - Analyzing Iowa Football Turnover Data for Improvement11 Sep 202200:09:05

In this episode, I read off a recent article I wrote, breaking down the turnover data from the University of Iowa 2021 football season. I explain how I would evaluate their data using categorization and Pareto charts to identify more opportunities to create more turnovers against their opponents, or reduce the number of turnovers caused, which will increase their chance of winning games.

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E62: 5S and the KonMari method18 Jun 202200:07:59

In this episode, I read off an article I wrote back a few years, about how the 5S workplace organization methods compare to the popular home organizing methods of Marie Kondo, developer of the KonMari method, which had become popular through her books and Netflix TV show. There are other links embedded within the article.

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E61: Lean in Real Life - Defining Key Metrics for a Project08 May 202200:05:13

In this episode, I discuss how I helped someone select a key metric for their Six Sigma project, based on the opportunity to measure and statistically validate the improvement.

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E60: Lean in Real Life - Selecting a Lean Six Sigma Project Within an Existing Project24 Apr 202200:07:37

In this episode, I discuss a way to help identify a potential Lean Six Sigma project out of a larger improvement project taking place. Selecting a project is one of the hardest things to complete for those pursuing a Lean Six Sigma certification.

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E59: Lean in Real Life - Improving Bottlenecks Using Theory of Constraints13 Apr 202200:06:39

In this episode, I discuss how I applied the Theory of Constraints (TOC) to come up with additional improvement ideas for a bottleneck process at a client I am working with. Before we invest in more people or equipment (throwing money at the problem), let's make sure we have extracted as much opportunity out of the existing process.

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