Explore every episode of the podcast The Lean Solutions Podcast
Dive into the complete episode list for The Lean Solutions Podcast. 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.
Rows per page:
50
1–50 of 299
Title
Pub. Date
Duration
Before You Invest: The AI Readiness Check
15 sept. 2026
00:26:31
What You'll Learn in This Episode:
In this episode, Catherine McDonald is joined by Dajana Achelpohl to explore the AI readiness gap. The difference between simply giving people access to AI and actually creating meaningful business value from it. They discuss why organizations can invest in AI tools, licenses, and pilot programs yet still struggle to see measurable results or sustained adoption.
Dajana introduces a practical five-question framework organizations can use to assess their AI readiness: Why? How? Who? What if? Then what? The conversation begins with understanding why AI is being introduced and connecting it to real business priorities rather than adopting it simply because everyone else is.
They also explore why organizations need to understand how work actually gets done before deciding where AI belongs. That means involving the people closest to the work, identifying bottlenecks and repetitive tasks, and integrating AI directly into workflows instead of treating it as another tool sitting alongside the work.
The conversation then turns to the people side of AI adoption, including AI literacy, leadership modeling, ongoing coaching, and giving employees the time and skills they need to become comfortable with new tools. Dajana also explains the importance of preparing for AI mistakes through human oversight, strong data practices, clear governance, and practical AI-use policies.
Finally, they discuss why AI adoption is not a one-and-done initiative. Organizations need to continuously learn, gather feedback, reinforce AI use through leadership, and determine what happens after pilot programs if they want AI adoption to stick.
Key Takeaways:
Having access to AI doesn't automatically create business value
Start with the business problem or opportunity—not the AI tool
AI must be integrated into how work actually gets done
Successful AI adoption requires bringing people along, building AI literacy, and modeling its use through leadership
What You'll Learn in This Episode: In this episode, Catherine McDonald is joined by Stephanie Angelo to explore why culture is the hidden process behind organizational performance. They discuss how organizations can improve processes all day long, but without a culture that supports trust, accountability, and engagement, those improvements are unlikely to stick.
Stephanie explains why company culture should be viewed as a business strategy and offers a simple way to understand it: the personality of an organization. The conversation explores how leaders can intentionally shape that personality through values, behaviors, policies, and everyday interactions—and why creating a strong culture requires active involvement from senior leadership, not just middle managers or HR.
The discussion also looks at psychological safety, differences in culture across teams, and the importance of creating alignment between departments. Stephanie shares practical insights into hiring for culture through behavior-based interviewing and explains how understanding a candidate's past behavior can provide a better picture of how they may contribute to an organization's culture.
Finally, Catherine and Stephanie explore the growing role of AI in the workplace and why it should be used as a tool to prompt, assist, and support human thinking rather than replace it. They discuss the potential for AI to support team communication and collaboration while emphasizing the need to maintain human judgment and intentionality.
Key Takeaways: 1. Culture is the hidden process that determines whether improvements truly stick 2. A strong company culture should be treated as an intentional business strategy 3. Culture is a shared responsibility, but senior leaders must actively model and support it 4. Hiring for culture requires understanding behaviors—not just skills and experience
In this episode, Patrick Adams and Andy Olrich are joined by Dr. William Harvey to explore one of the biggest challenges in continuous improvement: sustainment. Together, they discuss why organizations can be great at launching improvement initiatives but struggle to maintain momentum and achieve lasting results.
William identifies three fundamental conditions that influence whether improvement efforts stick: the work must feel meaningful, people must feel safe doing it, and they must have the time to do it. The conversation explores the critical role psychological safety plays in building ownership and engagement, along with how leaders can create trust by consistently listening to employees, removing obstacles, and following through on commitments.
The discussion also dives into Toyota Kata and deliberate practice as practical approaches for developing problem-solving capability throughout an organization. William explains how small experiments, daily coaching, and shared responsibility between coaches and improvers can turn continuous improvement from a temporary initiative into an everyday habit.
Whether you're leading a team, coaching problem solvers, building an improvement culture, or trying to prevent your latest initiative from becoming another "flash in the pan," this episode provides practical insights for creating an environment where continuous improvement can truly sustain.
Key Takeaways:
Sustainment requires meaningful work, psychological safety, and protected time
Leaders build trust by listening, removing barriers, and consistently following through
Continuous improvement must become part of the work—not something added on top of it
Toyota Kata builds problem-solving capability through deliberate practice and experimentation
What You'll Learn in This Episode: In this episode of the Lean Solutions Podcast, Natalie Howden is joined by Cindy Darnell, Steve Burgett, and Jordan Kimball for a preview of their sessions at the Lean Solutions Global Summit. Together, they explore how organizations can design better processes, reduce ambiguity, strengthen communication, and develop people through continuous improvement.
Steve and Jordan share how their work at Gentex focuses on designing systems that make problems visible, reduce noise and chaos, and create the stability needed for people to become proactive problem solvers rather than constant firefighters. They also discuss how these principles can be applied beyond manufacturing to support and administrative environments.
Cindy dives into DISC and how understanding different communication and behavioral styles can help leaders navigate change, strengthen teams, and support lean culture transformation. The conversation also explores the connection between people and innovation, the importance of understanding ourselves and others, and how Kata can become a powerful people development process.
Whether you're leading change, improving processes, developing people, or building a stronger continuous improvement culture, this episode offers practical insights for creating systems that work better and teams that work better together.
Key Takeaways: 1. Design processes to make problems visible and reduce ambiguity 2. Standardization and stability give people more room to problem-solve and innovate 3. Understanding different communication styles can make change more effective 4. People and innovation are better together when communication and systems support both
What You'll Learn in This Episode: In this episode of the Lean Solutions Podcast, Shayne Daughenbaugh and Andy Olrich welcome James Martin to explore why batching often feels more efficient, but can actually hurt the flow of an entire organization. James shares real-world examples of reducing batch sizes and moving toward flow, including a transformation that reduced processing time from 14 hours to as little as 1.5 hours while significantly increasing output.
The conversation explores how batching creates waiting, excess inventory, bottlenecks, and localized efficiency, and why teams need to focus on the flow of the entire system rather than individual productivity. James also explains how smaller batch sizes, experimentation, visual management, and employee empowerment can help organizations identify problems more quickly and foster a culture of continuous improvement.
Whether you're trying to reduce waste, improve manufacturing flow, or build a stronger continuous improvement culture, this episode offers practical examples of how reducing batching can help work move faster and more effectively through an organization.
In this episode, Patrick Adams is joined by Rebecca Moyers, Director of Operational Excellence for the State of Missouri, for a preview of her session at the Lean Solutions Summit, The Feedback Advantage. Rebecca shares how the State of Missouri is using employee and customer feedback to guide process improvement, strengthen experiences, and focus limited resources on the improvements that matter most.
The conversation explores how Missouri built an operational excellence community across 17 executive agencies, uses feedback to support both employee and customer experience, and applies omni-channel listening to better understand the entire customer journey. Rebecca also explains why organizations need to look beyond internal silos and consider whether every part of an experience connects seamlessly from the customer's perspective.
Rebecca shares practical examples of collecting feedback through website interactions, surveys, call centers, and operational data, and emphasizes that organizations shouldn't ask for feedback unless they're prepared to act on it. Most importantly, she explains that these principles aren't limited to government or large organizations; teams in virtually any industry can use intentional feedback to improve processes, culture, and the experiences they create.
Key Takeaways:
Feedback helps organizations focus improvement efforts on what matters most
Great customer experiences require looking at the entire journey—not individual silos
Employee and customer feedback become more powerful when paired with operational data
Don't ask for feedback unless you're prepared to act on it
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 program
Strong leadership is built through intentional behaviors and systems
AI should enhance human connection, not replace it
A successful AI strategy requires intentionality, transparency, and trust
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 solutions
Use hypothesis testing instead of educated guesses
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 environments
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.
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 improvement
2. Lean is learned best through hands-on experience
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.
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.
The First 90 Days of Lean: What Actually Matters (Part 1)
16 juin 2026
00:15:50
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.
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.
Leadership That Lasts: Respect, Stability, and the Human Side of Excellence
02 juin 2026
00:41:41
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 them 2. Great leadership requires stewardship, humility, and a commitment to developing others 3. Respect, stability, and psychological safety are essential foundations for continuous improvement 4. The future belongs to organizations that successfully combine technology, innovation, and human-centered leadership
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 adaptability
Scientific thinking is built through experimentation, reflection, and coaching
Psychological safety is essential for teams to admit uncertainty and learn
AI and emerging technologies increase the need for experimental thinking and continuous learning
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 preparation
Kaizen events fail when leaders don’t stay visibly engaged before, during, and after the work
Audits, visuals, standard work, and accountability systems help improvements stick
The strongest sign of success is when teams ask for more improvement work in their own areas
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 experiences
Coaching and curiosity develop better problem solvers than control and compliance
Small mindset shifts and micro habits can create meaningful leadership growth
Intentional praise helps leaders build resilience, perspective, and an abundance mindset
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 margins
Rework, poor flow, and “hot jobs” are major sources of cost leakage
Visibility through data, process mapping, and GEMBA is key to uncovering issues
Leadership behavior determines whether waste is allowed or eliminated
Gemba for Beginners: Why Leaders Need to Go See the Work
28 avr. 2026
00:32:27
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 assumptions
Leaders should approach the gemba with curiosity, not judgment
Trust is built through consistency, follow-up, and psychological safety
Start small—pick one process, observe, listen, and learn before acting
Better Behaviors, Better Outcomes: How Leaders Drive Change
21 avr. 2026
00:29:17
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 communication
Adapting your communication style improves collaboration and results
There is no “right” personality—diverse styles strengthen teams
Focus on strengths, not just weaknesses, to unlock better performance
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 time
Workarounds hide problems—don’t ignore them, fix them
What you tolerate becomes your process standard
Communication and psychological safety are essential for continuous improvement
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 concept
You can’t improve what you can’t see—data visibility is critical
Start small, but build a strong digital foundation
Ignoring technology debt creates major future risk
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 integration
2. Industry 4.0 is a journey, NOT a one-time project
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.
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 flow
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 impact
Technology should support people, not replace them
Leaders must coach and mentor to build a culture of improvement
Strategy must be translated so frontline teams understand their role
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.
The First 90 Days of Lean: What Actually Matters (Part 2)
24 févr. 2026
00:16:54
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 Tools
Your First 90 Days Should Focus on Leadership Development, Not Control
Create a “Sandbox” or Model Area to Learn Fast and Safely
The First 90 Days of Lean: What Actually Matters (Part 1)
17 févr. 2026
00:15:50
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.
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.
In 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 Takeaways
Coaching is a leadership approach, not an event.
Coaching is different from training and mentoring.
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 naturally
Why asking “who else should we talk to?” strengthens decisions and alignment
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 efforts
How a clear problem definition sets the foundation for success
Goal Setting That Sticks: Lean Your Way to Success in 2026
13 janv. 2026
01:00:34
The Lean Solutions Podcast hosts start off season 5 by addressing a common challenge: setting goals is easy, but making them stick is not. They emphasize that meaningful goal setting requires clarity, alignment, and intention, warning that vague goals and misaligned priorities often lead teams off track. From the start, they frame goals as something that must connect directly to daily work and organizational purpose.
They go on to highlight the importance of systems like leader standard work and visual management to support consistent execution. The hosts stress accountability rooted in psychological safety, regular check-ins, and a focused set of three to five goals supported by leading indicators. The episode concludes with a call to action for listeners to put these ideas into practice and ensure their goals align with both their organization’s objectives and culture.
Four Habits Every Leader Needs to Bring Into 2026
30 déc. 2025
00:46:43
What You’ll Learn:
Join the Lean Solutions Podcast hosts as they discuss the importance of reflection and goal-setting for 2026. They shared personal reflections on habits, such as overcooking presentations and non-use of talent, and the significance of being grounded and customer-focused. The team also discussed the eight wastes of lean to identify and improve personal habits.
In this episode, host Patrick Adams interviews Natalie Howden, a new team member at Lean Solutions, about her career journey and the importance of standard work in Lean environments. Natalie shares her background in pharmaceuticals, lithium-ion, and office furniture, highlighting her transition from a scientist to a Lean Six Sigma Black Belt. She emphasizes the value of standard work in achieving consistency and improving processes, using examples from her experience.
About the Guest:
As an Executive Lean Coach at Lean Solutions, Natalie Howden helps organizations transform how they operate by reducing waste, accelerating flow, and embedding continuous improvement into everyday culture. Lean Solutions’ mission is to empower people through training, coaching, and talent solutions. Building the skills, systems, and culture needed for sustainable success.
Partnering with organizations across manufacturing, healthcare, services, and professional industries, Natalie identifies inefficiencies and quality gaps and applies proven lean tools to redesign processes and deliver greater value with fewer resources. Through coaching leaders and teams, she builds lasting problem-solving capabilities and drives sustained performance by aligning systems, structures, and behaviors with lean thinking.
In this episode, host Catherine McDonald and guest Kelly Mallery discuss the importance of understanding and managing resistance to change in the workplace. They emphasize that resistance is a natural human reaction rooted in fear and that fighting it can be counterproductive, leading to eroded trust and failed change initiatives.
About the Guest:
Kelly Mallery has built her career helping teams and leaders navigate change—not by pushing harder, but by making the process easier, smarter, and even enjoyable. As the Operational Excellence Leader for two Viant Medical sites in New Hampshire and Michigan, she drives continuous improvement in high-stakes manufacturing environments. With over a decade of experience across solar, industrial consumer products, and aerospace, Kelly believes true transformation starts with mindset, not just tools.
Through her coaching and consulting work, Kelly helps women change leaders overcome resistance, build confidence, and create lasting impact with less struggle. A proud Kata geek, she joined Kata Girl Geeks in 2020 and founded Kata School Northeast in 2023 to expand scientific thinking and adaptability. She lives in the Upper Valley between Vermont and New Hampshire with her family, where she continues her mission to make change work for people—not against them.
Positive Leadership: The Foundation of Continuous Improvement
09 déc. 2025
00:32:52
What You’ll Learn:
In this episode, hosts Andy Olrich, Catherine McDonald, and guest Wendy Sellers discuss positive leadership. They define positive leadership as focusing on strengths, optimism, and psychological safety, which fosters continuous improvement through ongoing learning and experimentation. They emphasize the importance of accountability, high standards, and clear company values. Wendy shares her experience with both positive and negative leadership, highlighting the need for realistic, respectful, and encouraging management.
About the Guest:
Wendy Sellers, The HR Lady®, is a nationally recognized HR Consultant, Speaker, Trainer, Podcaster, Author, and Mentor, as seen in USA Today and the International Business Times. Known for her direct, no-nonsense approach delivered with respect, Wendy empowers organizations to treat people as their greatest asset. She equips leaders, managers, and administrators with the skills and confidence needed to navigate HR compliance, workplace culture, and the full employee lifecycle—from hiring to termination.
With 30 years of experience across for-profit, non-profit, government, and defense organizations, Wendy brings a rare blend of practical insight and strategic vision. Her career began unexpectedly in an Orlando engineering firm and grew alongside the company’s national and global expansion. Backed by multiple degrees and HR certifications, Wendy is driven by a clear mission: to help leaders build successful companies that employees don’t feel the need to escape.
In this episode, hosts Andy Olrich, Shayne Daughenbaug, and guest Alex Suchman discuss how play can serve as a powerful tool for continuous improvement and stronger team performance. They highlight how workplace disagreement often stems from interpersonal dynamics and different communication styles. They also emphasize that play can foster trust, accountability, and psychological safety.
About the Guest:
Alex Suchman is the CEO and co-founder of Barometer XP, whose mission is to create cultures where people are excited about their work because they feel a strong sense of purpose and belonging. She uses games and play to strengthen interpersonal dynamics, such as trust, accountability, and psychological safety, in the workplace. She was a finalist for the Metro DC ATD Award for Excellence in Innovative Learning, has been featured in Forbes, and is a sought-after speaker and thought leader on using play as a tool for organizational effectiveness and employee success.
Spotlight Episode: People First - The Soft Skills Advantage
25 nov. 2025
00:43:21
What You’ll Learn:
In this episode, hosts Patrick Adams and Andy Olrich discuss the importance of soft skills in leadership, emphasizing empathy, communication, adaptability, and emotional intelligence.
About the Guest:
Andy Olrich brings over 25 years of expertise in engineering trades, services, manufacturing, mining and logistics processes and support. With qualifications in Continuous Improvement and LEAN Six Sigma, he is also a Certified Scrum Master. Andy finds fulfillment in witnessing the positive outcomes that result from teams collaboratively working towards shared and individual goals.
Patrick Adams is an internationally recognized leadership coach, consultant and professional speaker. He is best known for his unique human approach to sound team building practices, creating consensus and enabling empowerment.Patrick has been delivering bottom-line results through specialized process improvement solutions for over 20 years. He’s worked with all types of businesses from private, non-profit, government, and manufacturing ranging from small business to billion-dollar corporations. Patrick is an Author of the best selling book, Avoiding the Continuous Appearance Trap.
Spotlight Episode: Sustaining Culture and Connection
18 nov. 2025
00:42:10
What You’ll Learn:
In this episode, hosts Catherine McDonald, Andy Olrich, and guest Leire Martinez discuss the importance of sustaining culture and connection in organizations. They emphasize that culture is crucial for continuous improvement and can vary across different departments and regions.
About the Guest:
With a strong Lean Six Sigma background, she is experienced as an Operations Director managing multi-site operations, as well as a Plant Manager, Production Manager, and Continuous Improvement Manager in the automotive sector within a VUCA environment and during challenging periods such as COVID, the chip crisis, and material shortages. Her aim is to inspire the teams she works with to achieve results as one, always acting with integrity, a willingness to win, and a commitment to making tomorrow better.
What You’ll Learn: Patrick Adams discusses his experience on the "Blox" show, a live startup competition. He was motivated by the opportunity to learn and apply new skills to his business, Lean Solutions. The show, which features 100-150 businesses, is hosted by Wes Bergman and involves daily classroom sessions and challenges. Patrick emphasizes the importance of simplifying business explanations and making them accessible to non-lean practitioners. He highlights the value of networking, the competitive yet supportive environment, and the exhaustion from the intense week-long filming. The show is available on the Blocks app, Facebook, and their website.
Catalysts of Tomorrow: Lean Solutions Competition
04 nov. 2025
00:44:39
What You’ll Learn:
In this episode, host Patrick Adams welcomes Andy Olrich and John Dyer to discuss their experiences at the Lean Excellence World Championship. They share insights into the diverse strategies teams employed to tackle a common challenge and emphasize the critical roles of customer engagement and supplier analysis. Despite early obstacles, the winning team distinguished itself through data-driven decision-making. The competition’s real-world scenarios and collaborative dynamics offered valuable learning opportunities for all participants.
Why Your Process Improvement Efforts Stop After the First Year
28 oct. 2025
00:40:51
What You’ll Learn:
In this episode, host Patrick Adams and guest Craig Tedrow discuss the importance of long-term sustainment in organizational processes. Craig shares his journey from resisting Lean practices to embracing them, emphasizing the need for leaders to involve employees and revisit improvements regularly. They highlight the significance of clear expectations, enabling action, and sustaining improvements.
About the Guest:
Craig Tedrow is an experienced Continuous Improvement professional with a strong background in the automotive, aerospace, and defense industries. Known for his ability to bridge the gap between frontline workers and organizational goals, he brings expertise in training coordination, process improvement, and team development. With an Associate’s degree in Computer and Information Sciences from Grand Rapids Community College, Craig combines technical understanding with a people-centered approach to leadership.
In this episode, hosts Patrick Adams and Andy Olrich discuss Andy's recent trip to the US for the Lean Solutions Global Summit. Andy, was a speaker and judge at the summit’s Lean Solutions Competition. He notes the success of advanced manufacturing centers and the importance of lean and best practice tools. Patrick and Andy reflect on the new Lean Solutions office, emphasizing its immersive training environment and community service.
About the Guest:
Andy Olrich is a Business Improvement Specialist with over 25 years of experience driving meaningful change across industries including Mining, Manufacturing, Ports, Supply Chain and Logistics, Health, and Government services. With a strong foundation in trades and engineering, Andy has led Operations and Maintenance teams while leveraging formal expertise in Lean, Lean Six Sigma, Change Management, Agile, and related disciplines.
Known for his energetic facilitation and people-focused approach, Andy combines a customer-centric mindset with a deep commitment to community engagement. As an international speaker, coach, and co-host of the Lean Solutions Podcast, he empowers individuals and organizations to enhance processes, reduce risk, improve customer experiences, and deliver sustainable outcomes.
Military Leadership Principles for Continuous Improvement
14 oct. 2025
00:45:39
What You’ll Learn:
In this episode, host Shayne Daughenbaugh and guest Lee Campe discuss the application of military leadership principles to continuous improvement. Lee shares his extensive experience across various industries, emphasizing the importance of clear communication, training, and decision-making under pressure. They discuss the need for leaders to be part of the team, set a good example, and ensure effective training and communication to drive continuous improvement.
About the Guest:
Lee Campe is one of the nation’s leading experts in metric development, KPIs, problem solving, and process management. A Lean Six Sigma Master Black Belt, Lee brings decades of experience across industries, including retail, pharmaceuticals, medical devices, food manufacturing, healthcare, automotive, and even space exploration. His unique perspective blends technical excellence with practical leadership drawn from his service as a U.S. Army Airborne Ranger, and as a proud father of two daughters. In this episode, Lee shares how military leadership principles, forged through experience in both the Army and Marine Corps, can be applied to continuous improvement in honor of the U.S. Army’s 250th birthday.
In this episode, host Catherine McDonald, Patrick Adams, and guest Tina Patel Gunaldo discuss interprofessional collaboration. They explain the importance of interprofessional education (IPE) in training future healthcare professionals to collaborate effectively. Tina highlights the challenges of traditional hierarchies and the need for asynchronous collaboration.
About the Guest:
Tina is an innovative and results-driven healthcare leader dedicated to advancing interprofessional collaboration and patient-centered care. She is known for transforming visionary ideas into lasting, evidence-based systems that improve access, quality, and performance across clinical, academic, and community settings. With a proven track record of developing scalable models, securing multimillion-dollar funding, and launching initiatives adopted statewide and nationally, Tina brings together clinicians, administrators, educators, and community partners around shared goals that elevate both patient care and organizational excellence. Her work includes pioneering Louisiana’s first hospital-based food pantry, establishing the state’s first Interprofessional Consortium, and developing vaccination training programs for dentists. Guided by the principles of empowering patients as leaders of their health teams, fostering interdependence, and embedding evidence-based teamwork into practice, Tina continues to inspire innovation and collaboration in healthcare.
Bridging the Gap: Aligning Technology with Innovation
30 sept. 2025
00:53:32
What You’ll Learn:
In this episode, hosts Shayne Daughenbaugh, Andy Olrich, and guest Claire Quigley discuss the gap between technological capabilities and business outcomes. They emphasize an understanding of the purpose of transformation, aligning leadership and people, and ensuring clear communication and change management.
About the Guest:
Claire Quigley is the founder of Launchpad9, a boutique consultancy dedicated to inspiring and empowering meaningful innovation in established organizations. Claire brings a unique perspective shaped by her journey through high-tech startups, SMEs, and large corporations, where she has learned firsthand what truly works—and what doesn’t—when it comes to forming and executing innovation and growth strategies that make a real difference.