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Lean Six Sigma Bursts

Lean Six Sigma Bursts

By Brion Hurley

Brion Hurley from Business Performance Improvement shares his takes and thoughts on a variety of topics related to process improvement (specifically Lean and Six Sigma methods), Bursts are rapid improvement activities, so this sounded like a good word to use for these short audio clips. We'll try to keep them under 10 minutes each. Have a question? Use the Spotify app to leave us a voice message, and we might pick your question for our next episode!
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E143: Why LSS Leads to Better Improvements and Cost Reductions

Lean Six Sigma BurstsSep 21, 2026
00:00
09:53
E143: Why LSS Leads to Better Improvements and Cost Reductions

E143: Why LSS Leads to Better Improvements and Cost Reductions

In this episode, I took a module from the Lean Six Sigma and the Environment course, and cleaned it up with AI to make it easier to listen to (due to background noise).


I discuss an overview of Lean and Six Sigma and how companies can make bad decisions when only focused on cost reductions.


I also share some examples of how Lean Six Sigma has helped companies


To download the 40+ case studies I mentioned, go to https://www.leansixsigmaecosystem.com/c/templates/40-environmental-lean-six-sigma-case-studies


The Lean Six Sigma and the Environment course will be available at LeanSixSigmaEcosystem.com in the next month or so.


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Sep 21, 202609:53
E142: Lean Six Sigma Challenges with Sustainability

E142: Lean Six Sigma Challenges with Sustainability

In this episode, I took a module from the Lean Six Sigma and the Environment course, and cleaned it up with AI to make it easier to listen to (due to background noise).

Earlier in the course, I discussed how Lean and Six Sigma could help reduce environmental impacts, sometimes without even trying.

However, there are reasons why these impacts are overlooked in improvement methods, which I explain in this clip.


The course will be available at LeanSixSigmaEcosystem.com in the next month or so.


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Sep 13, 202607:52
E141: Hidden Costs of Equipment Downtime

E141: Hidden Costs of Equipment Downtime

In this episode, I discuss a big opportunity to improve success in your manufacturing facility, reducing equipment downtime.

Most people are only focused on the lost labor when equipment isn't running, but what about the lost opportunity to produce valuable products that could be sold to a customer?

If you're looking for a good improvement project, collecting data on your downtime and calculating these costs might uncover a potential project you can work on.


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Jul 24, 202610:17
E140: Applying Six Sigma's IPO (Inputs Process Outputs) to your Personal Life

E140: Applying Six Sigma's IPO (Inputs Process Outputs) to your Personal Life

In this episode, I discuss an important concept in Six Sigma:

Y = f(x) or Y is a function of x.

Y is your measured output, and X represents the inputs to your process, and the function represents the process and how the X factors relate or impact the Y.

Another way to state it is Inputs (X), Processes (Function) and Outputs (Y) or IPO.

I explain how this concept can be used when thinking through your own personal improvement journey. What are your inputs, processes and outputs.

If you don't like how one of the outputs is performing (relationships, weight, health, income, etc), then what processes and inputs need to change.

Listen to the episode to learn more. If you'd like the graphic I mentioned, send me an email at brion@biz-pi.com


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Jun 22, 202612:50
E139: Six Common Types of Process Improvement Projects for Lean Six Sigma Certification

E139: Six Common Types of Process Improvement Projects for Lean Six Sigma Certification

In this episode, I summarize 6 different types of projects you can use for a Lean Six Sigma certification

  1. Improve Quality
  2. Reduce Speed and Time
  3. Reduce Cost and Consumption of Resources
  4. Reduce Risk
  5. Improve Capacity and Flow
  6. Improve Experience and Satisfaction Ratings


I also share examples of each across 4 industries: Manufacturing, Office, Government and Healthcare


You can also read about these 6 types by going to https://greenbeltcertification.com/2026/05/17/common-types-of-process-improvement-projects-for-lean-and-six-sigma-certification-programs/


I also mentioned that there are a long list of project ideas by industry and department, which can be found at https://www.biz-pi.com/lean-and-six-sigma-project-ideas/


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May 17, 202614:26
E138: Using Employee Surveys and Paired t tests for Measuring Improvement

E138: Using Employee Surveys and Paired t tests for Measuring Improvement

In this episode, I discuss a specific method for capturing process improvements using surveys, and how you can isolate the improvements so that the difference between survey participants doesn't hide the results.


I also referenced a similar survey I conducted (Episode 77), where I shared the survey results at a company after implementing a daily huddle.

You can check out episode #77 from June 2023 at https://podcasts.apple.com/us/podcast/e77-client-survey-shows-daily-huddles-improve-communication/id1529478357?i=1000615545292

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May 04, 202607:58
E137: Lean Six Sigma Training Simulations and Exercises

E137: Lean Six Sigma Training Simulations and Exercises

In this episode, I share a list of the simulations I use in my training classes to teach Lean and Six Sigma methods and techniques.

To see the entire list, go to https://greenbeltcertification.com/lean-six-sigma-training-simulations/


If you'd like to attend the Green Belt with Copilot Part 2 webinar, I had to reschedule to April 13th. I'll go through ANOVA, DOE, Regression and other hypothesis tests using Copilot. You can still register at ⁠⁠https://www.leansixsigmaecosystem.com/c/webinars/green-belt-refresher-using-copilot-part-2⁠⁠


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Apr 06, 202611:12
E136: Review of DMAIC Roadmap for Improvement Projects

E136: Review of DMAIC Roadmap for Improvement Projects

In this episode, I share the kickoff to last week's webinar called "Green Belt Refresher using Copilot - Part 1" where I do a quick refresher of the DMAIC roadmap taught in Green and Black Belt training programs. A good refresher for those who have previously taken a course, or for those new to DMAIC.


To listen to the entire webinar, where I show how Copilot compares with Minitab for graphical analysis, summary statistics, SPC and capability analysis, go to ⁠https://www.leansixsigmaecosystem.com/c/webinars/green-belt-refresher-using-copilot-part-1 ⁠


If you'd like to also attend next month's Part 2 webinar, where I'll go through ANOVA, DOE, Regression and other hypothesis tests using Copilot, you can register at ⁠https://www.leansixsigmaecosystem.com/c/webinars/green-belt-refresher-using-copilot-part-2⁠


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Mar 25, 202608:15
E135: Future of Six Sigma software and AI

E135: Future of Six Sigma software and AI

In this episode, I share the kickoff to last week's webinar called "Green Belt Refresher using Copilot - Part 1" where I discuss the reason for the webinar, and what the current challenges are with teaching Six Sigma with different statistical software packages.


To listen to the entire webinar, where I show how Copilot compares with Minitab for graphical analysis, summary statistics, SPC and capability analysis, go to https://www.leansixsigmaecosystem.com/c/webinars/green-belt-refresher-using-copilot-part-1


If you'd like to also attend next month's Part 2 webinar, where I'll go through ANOVA, DOE, Regression and other hypothesis tests using Copilot, you can register at https://www.leansixsigmaecosystem.com/c/webinars/green-belt-refresher-using-copilot-part-2


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Mar 09, 202605:24
E134: Free Virtual Lean Project Program for Nonprofits

E134: Free Virtual Lean Project Program for Nonprofits

Feb 05, 202603:08
E133: Does a Six Sigma Green/Black Belt Certification Boost My Salary?

E133: Does a Six Sigma Green/Black Belt Certification Boost My Salary?

This episode is from an article I wrote a few months ago in response to questions about Six Sigma certification and the impact on your salary and promotions.

In summary, a Six Sigma Green Belt or Black Belt certification can lead to:

  • Higher average salaries
  • Faster raises and promotions
  • Broader career opportunities like leadership and consulting
  • Improved problem solving skills that deliver real business value

To learn more about Six Sigma Green Belt and Black Belt certification, go to https://greenbeltcertification.com/lean-six-sigma-green-and-black-certification-programs/https://greenbeltcertification.com/lean-six-sigma-green-and-black-certification-programs/


The full article can be found at: https://greenbeltcertification.com/does-a-six-sigma-green-belt-or-black-belt-certification-increase-my-salary/

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Jan 27, 202610:20
E132: Announcing free course "Applications of Lean in Healthcare"

E132: Announcing free course "Applications of Lean in Healthcare"

In the ⁠Lean Six Sigma Ecosystem⁠, I have posted numerous courses over the past few months, and quite a few of them are free.

If you're not aware, the adoption of Lean in the healthcare industry has been pretty dramatic over the past 20+ years.

I took some of the best healthcare-specific Lean training videos I've used in my Lean Six Sigma courses and compiled them into one online course, called Applications of Lean in Healthcare 

The course includes 27 lessons (over 3 hours of online learning).

You will learn how Lean has been applied at:

  • Harbor-UCLA Medical
  • Virginia Mason
  • Miami Children's
  • Washington Hospital
  • Bahri Dental Group
  • Riverside University
  • Cleveland Clinic.

You will also learn how these improvement tools have been implemented specifically in healthcare:

  • 8 Wastes
  • 5S
  • Daily and Tiered Huddles
  • Spaghetti Diagrams
  • Value Stream Mapping
  • Model cells
  • Takt time
  • 2-bin kanban system
  • 3P
  • Training within Industry (TWI)
  • Six Sigma

This is such an important topic that we wanted to make this training FREE

Want to take this free course?

  1. Sign up for a free account
  2. Navigate to the Courses section and select "Applications of Lean in Healthcare"
  3. Complete the course

Do you have friends and family in healthcare or the medical industry?


Please share the course link or forward this email to them. This might be the training that has a significant impact on their career.


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Dec 17, 202503:05
E131: The Big 3 Quality Improvement Tools for the Food and Beverage Industry

E131: The Big 3 Quality Improvement Tools for the Food and Beverage Industry

The following is the summary of the December 3rd webinar I presented called "Quality Improvement Tools for Food and Beverage Manufacturing"

I just edited the webinar and turned it into a course in Lean Six Sigma Ecosystem. Although it is geared towards the food and beverage (F&B) industry, it is open to those from any industry looking to improve quality, reduce variation and increase the success of meeting customer specification and tolerances.

You will learn about these 3 tools:

  • Statistical Process Control (SPC)
  • Measurement Systems Analysis (MSA)
  • Capability Analysis (Cp/Cpk vs Pp/Ppk)

To sign up for this course, go to https://www.leansixsigmaecosystem.com/c/the-big-3-quality-improvement-tools-for-the-food-and-beverage-industry


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    • Want to get certified in Lean Six Sigma, but not sure where to start? Visit help me choose a certification to decide what will be best for your career




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    Dec 10, 202509:13
    E130: The Importance of Process Logs in Problem Solving

    E130: The Importance of Process Logs in Problem Solving

    In this podcast, I share details about a tool that I call "Process Log" but maybe you've heard it called something else.


    It's an approach to documenting changes, observations and other activities that happen in a work area on a daily basis, so you can reference them in the future.


    I also recommended checking out the Root Cause Analysis course, where you can learn about the 6 M's


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    Oct 22, 202506:16
    E129: History of Lean (part of new LSS White Belt course)

    E129: History of Lean (part of new LSS White Belt course)

    In this podcast, I share a module from the new Lean Six Sigma White Belt course I have recently released for free on the LeanSixSigmaEcosystem.com platform.


    This module describes a quick history of Lean (or Toyota Production System) and how it evolved from the US to Japan and back to the US.



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    Oct 16, 202509:24
    E128: TQM at the State of Iowa began in 1992?

    E128: TQM at the State of Iowa began in 1992?

    In this podcast, I share one of the articles I found from October 1992 about a government efficiency program at the State of Iowa, called Total Quality Government.

    I read through the article and share my thoughts about how it morphed into their modern improvement program.


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    Sep 23, 202512:35
    E127: What is Lean Coffee and Unconferences?

    E127: What is Lean Coffee and Unconferences?

    In this podcast, I share a short presentation I gave about the concept of Lean Coffee this week. It is an informal meeting structure where participants brainstorm topics and vote on what gets discussed. An alternative to spending time planning and guessing what people want to talk about or learn.I also explain how it differs but is similar to an unconference.You can learn more about the origin of Lean Coffee at https://leancoffee.org/You can also watch a video of this short presentation at https://www.youtube.com/watch?v=i7dkReGPg58


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    Sep 04, 202507:59
    E126: Intro to Nonparametric Statistics (Part 2 of 2)

    E126: Intro to Nonparametric Statistics (Part 2 of 2)

    In this podcast, I share the second section of a course I'm creating for ⁠Lean Six Sigma Ecosystem⁠ called "Nonparametric Statistics"


    Nonparametrics are an alternative way of analyzing data, but instead of using means and standard deviations traditionally taught in Green Belt and Black Belt classes, it uses median and quartiles or percentiles. The calculations are simpler, and there are often less assumptions required (like requiring data to fit a normal distribution).


    If you sign up for a free account on ⁠Lean Six Sigma Ecosystem⁠⁠, you'll be notified when the full course is ready.



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    Aug 18, 202505:54
    E125: Intro to Nonparametric Statistics (Part 1 of 2)

    E125: Intro to Nonparametric Statistics (Part 1 of 2)

    In this podcast, I share the first two sections of a course I'm creating for Lean Six Sigma Ecosystem called "Nonparametric Statistics"


  • Nonparametrics are an alternative way of analyzing data, but instead of using means and standard deviations traditionally taught in Green Belt and Black Belt classes, it uses median and quartiles or percentiles. The calculations are simpler, and there are often less assumptions required (like requiring data to fit a normal distribution).

  • If you sign up for a free account on Lean Six Sigma Ecosystem⁠, you'll be notified when the full course is ready.



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    Aug 09, 202507:29
    E124: Using Lean Six Sigma to Reduce Patient Medication Complications (Audio by AI)

    E124: Using Lean Six Sigma to Reduce Patient Medication Complications (Audio by AI)

    In this podcast, I share the summary of a project I worked on almost 20 years, but is still relevant today.

    A grant was awarded to the Cedar Rapids (IA) community to study anticoagulation management using Lean and Six Sigma. One of the key analysis performed in the project was a Gage Repeatability and Reproducibility (R&R) study. We wanted to determine if blood samples taken from a patient on warfarin have the same International Normalized Ratio (INR) results when analyzed in different labs (reproducibility) and when analyzed multiple times in the same lab (repeatability).

    Results showed a statistically significant difference among labs. The therapeutic range for INR is typically 2.0 to 3.0, yet the data showed a difference in INR of 0.5 among labs on a small sample of 10 warfarin patients, almost 50 percent of the range.

    By the way, this entire podcast was spoken by my AI voice created by Eleven Labs.


    Links for this episode:



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    Jul 16, 202514:01
    E123: Applying Net Promoter Score (NPS) to a Zero Waste Conference (Audio by AI)

    E123: Applying Net Promoter Score (NPS) to a Zero Waste Conference (Audio by AI)

    In this episode, I share a clip from the book chapter I wrote for "Lean Six Sigma for Good: Lessons from the Gemba" Volume 1. I explain how I used net promoter score (NPS) to assess the attendee feedback of a fundraising conference I helped organize.

    By the way, this entire podcast was spoken by my AI voice created by Eleven Labs.


    Links for this episode:



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    Jul 01, 202505:25
    E122: Applying Risk Management to Conference Planning (Audio by AI)

    E122: Applying Risk Management to Conference Planning (Audio by AI)

    In this episode, I share a clip from the book chapter I wrote for "Lean Six Sigma for Good: Lessons from the Gemba" Volume 1. I explain how I used risk management methods to reduce the chance of problems when planning my first fundraising conference.

    By the way, this entire podcast was spoken by my AI voice created by Eleven Labs.


    Links for this episode:



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    Jun 23, 202509:07
    E121: I can help you become a Lean Six Sigma "rockstar"!

    E121: I can help you become a Lean Six Sigma "rockstar"!

    In this podcast, I explain a virtual coaching and mentoring program that will be starting next week.


    Whether you’re rolling out a new project, stuck on data analysis, or facing resistance to change, you need specific help for your unique situation that aligns within your company culture.


    You’re already solving problems. Now I'd like to help you solve them faster, with less frustration, and more impact.


    Here are the highlights of getting coaching from a Lean Six Sigma Master Black Belt

    • Two group coaching sessions (90 minutes each on Zoom, every other week, recorded if cannot attend) – $450 value
    • One 30-min private coaching call per month (if group call isn’t enough) – $75 value
    • Will group you with others based on skills, experience and needs (see details below)
    • Learning modules, templates and guides to refresh you on improvement concepts and methods – $2500 value
    • Only $50/week – cancel anytime (no contracts)

    Go to https://greenbeltcertification.com/lean-six-sigma-virtual-coaching-calls/ to learn more about the program.


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    Jun 15, 202510:14
    E120: Lean at Home - Reducing External Storage Space Costs

    E120: Lean at Home - Reducing External Storage Space Costs

    In this podcast, I share the results of a "Lean at Home" project I performed within the last year as part of a training and certification program I piloted with my friends and family.


    The project successfully reduced our storage costs per month by over 50%, and then 100% within the past few weeks!


    You can download the project summary here: http://www.leansixsigmahomes.com/wp-content/uploads/2025/05/Lean-at-Home-Project-Storage-Unit-2024.pdf



    If you have an example, please share it with me on LinkedIn.


    Go to LeanSixSigmaHomes.com to find many more examples of improvements at home using Lean and Six Sigma methods. You will also see the link to access the training and certification program for $49.


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    May 07, 202511:32
    E119: Why DOGE should utilize Lean Six Sigma like Pete Ricketts did in Nebraska

    E119: Why DOGE should utilize Lean Six Sigma like Pete Ricketts did in Nebraska

    In this podcast, I share the audio from a video of a speech given by former Nebraska governor and current US Senator, Pete Ricketts. He discusses how Nebraska used Lean Six Sigma to improve their services to residents, reduced costs, building space and time. He encourages the Department of Government Efficiency (DOGE) to utilize a similar approach.


    You can watch the video at https://www.youtube.com/watch?v=1JwDhbZBXCI


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    Apr 11, 202510:46
    E118: Real-life Examples of Hypothesis Testing

    E118: Real-life Examples of Hypothesis Testing

    The following was a clip from a recent presentation, where I discuss how hypothesis testing can help you draw more statistically valid conclusions from data, and avoid misleading or incorrect conclusions.

    I share two examples. The first was a data set from the Denver Sheriff's Department, where they graphed and analyzed intake use of force incidents, but their conclusions don't seem to match the graphic.

    The 2nd example was data I pulled for a nonprofit I ran that showed the day of the week and time of day had no impact on click through rates on our monthly email newsletter.


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    Mar 05, 202506:39
    E117: The Importance of Data and the 1948 Presidential Election

    E117: The Importance of Data and the 1948 Presidential Election

    The following was a clip from a recent presentation, where I discuss the importance of data in improvement (seems obvious, yet not always present).

    I also share the unique situation that happened in the 1948 Presidential Election when polling data was biased towards the candidate that lost. As I dug deeper into this story, I don't see where they specifically mention the phone, but there was a problem with the accuracy of the polling. It also mentions that Truman was gaining momentum late in the election, and that wasn't reflected in the polls. Nonetheless, the Chicago Tribune ran their infamous headline that Dewey had won the election, when Truman actually won.


    You can learn more about that strange election at https://en.wikipedia.org/wiki/1948_United_States_presidential_election

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    Feb 20, 202506:15
    E116: How a battery manufacturer saved nearly $1 million by completing only 7 Lean Six Sigma projects

    E116: How a battery manufacturer saved nearly $1 million by completing only 7 Lean Six Sigma projects

    In this podcast, I share a successful case study of a Lean Six Sigma training and certification program conducted for a battery manufacturer about 2 years ago. By completing real-life projects, they were able to payback the investment in the training in under one month!

    Links


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    Jan 16, 202509:03
    E115: How I use AI for my Lean Six Sigma Consulting

    E115: How I use AI for my Lean Six Sigma Consulting

    In this episode, I share a short segment of a recorded presentation I gave to the Continuous Process Improvement Forum hosted within the National Industries of the Blind. They wanted to hear my perspective on AI, so I shared how I've utilized for my consulting work.

    NIB is a great organization whose mission is to enhance the opportunities for economic and personal independence of people who are blind, primarily through creating, sustaining, and improving employment.

    Links

    • National Industries for the Blind: https://nib.org/

    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/⁠⁠⁠⁠⁠⁠⁠⁠⁠⁠⁠

    Dec 12, 202405:01
    E114: Tackling Green with Lean - Energy Treasure Hunts

    E114: Tackling Green with Lean - Energy Treasure Hunts

    In the 2024 Lean Global Connection virtual conference, our Lean Sustainability community shared some tips and methods to help apply Lean to Green initiatives.

    In my segment, I explained how Energy Treasure Hunts are a combination of gemba walks and kaizen events, with the goal to identify and reduce energy usage in a facility. This is a great approach that combines my passion for process improvement and sustainability.

    The full presentation will be available in a few weeks (end of 2024), and I will post it in the Lean Six Sigma for Good podcast as soon as possible.

    Links

    • Lean Global Connection: https://www.planet-lean.com/lean-global-connection-2024
    • Video from this presentation segment: https://youtu.be/OD0aZK8JptM
    • Energy Treasure Hunts Webinar: https://leansixsigmaenvironment.org/index.php/e116-using-energy-treasure-hunts-and-energy-swaps-to-engage-employees-and-reduce-costs/
    • About the Lean Sustainability Community: https://leansixsigmaenvironment.org/index.php/lean-sustainability-global-network/

    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/⁠⁠⁠⁠⁠⁠⁠⁠⁠⁠

    Nov 25, 202410:30
    E113: Explaining Energy Treasure Hunts with AI

    E113: Explaining Energy Treasure Hunts with AI

    Energy Treasure Hunts can be described as a combination of gemba walks and kaizen events in Lean methodology, with the goal to identify and reduce energy usage in a facility. This is a great approach that combines my passion for process improvement and sustainability.

    I uploaded a recent webinar I did on Energy Treasure Hunts to AI (NotebookLM), and it generated a fake podcast episode between two robots, which was mind-blowing to hear.


    I share segments from the "podcast" so you can hear how it sounds. Let me know what you think!


    In summary, here is how NotebookLM summarized the webinar, which was well-stated:

    "Energy treasure hunts and programs like the Better Buildings Challenge offer a powerful approach to identifying and implementing energy-saving opportunities. By engaging employees, leveraging data analysis, and fostering collaboration, organizations can achieve significant energy reductions, cost savings, and environmental benefits."


    Links

    • NotebookLM from Google: https://notebooklm.google.com/
    • Energy Treasure Hunts Webinar: https://leansixsigmaenvironment.org/index.php/e116-using-energy-treasure-hunts-and-energy-swaps-to-engage-employees-and-reduce-costs/

    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/⁠⁠⁠⁠⁠⁠⁠⁠⁠

    Nov 01, 202409:32
    E112: Lean Six Sigma for Good

    E112: Lean Six Sigma for Good

    In the last 2 episodes, I shared best practices in process improvement with students in the Florida Atlantic University (FAU) Executive MBA Program⁠ in Boca Raton, Florida.

    At the end of my talk, I discussed how Lean and Six Sigma can be used to improve society and the environment, which I call Lean Six Sigma for Good. I share some examples and discuss my own experiences, hand out copies of Volume 1 and 2 of the book series, and encourage the students to help me connect with some local nonprofits.

    Additional Links

    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/⁠⁠⁠⁠⁠⁠⁠⁠

    Oct 23, 202411:46
    E111: Lean Six Sigma Best Practices - Part 2

    E111: Lean Six Sigma Best Practices - Part 2

    This is the 2nd part of the list of best practices in process improvement I shared with students in the Florida Atlantic University (FAU) Executive MBA Program⁠ in Boca Raton, Florida last month. I compiled my top recommendations that they could take back to their company.

    • Daily huddles to review performance and formalize communication
    • Statistical thinking and analysis (separating noise from signals)
    • Leaders as coaches and mentors (secret to Toyota)
    • Must create time for risk prevention, kaizen events and projects

    Additional Links

    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/⁠⁠⁠⁠⁠⁠⁠

    Oct 14, 202409:57
    E110: Lean Six Sigma Best Practices - Part 1

    E110: Lean Six Sigma Best Practices - Part 1

    This is a list of best practices in process improvement I shared with students in the Florida Atlantic University (FAU) Executive MBA Program⁠ in Boca Raton, Florida last month. I compiled my top recommendations that they could take back to their company.

    • Focused on building problem solving and waste identification skill set of lowest-level employee
    • Psychological safety to discuss and solve problems
    • Management horizontally across value stream
    • Making decisions that are best for the system, not individual departments (vertical)
    • Aligned and balanced metrics (two-way communication or “catchball”)
    • Not just lagging financial metrics


    Additional Links

    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/⁠⁠⁠⁠⁠⁠

    Oct 09, 202407:45
    E109: The Lean Journey at Rockwell Collins with Clay Jones - Part 6

    E109: The Lean Journey at Rockwell Collins with Clay Jones - Part 6

    This is the final part 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, he answers audience questions:

    1) How to immerse Lean into the culture?

    2) How is he going after employee healthcare costs? (asked by George Koenigsaecker)

    3) What are the biggest barriers he is concerned about?


    In his answers, he mentions the importance of coaching and mentoring, but also discusses the classroom and virtual training courses, knowledge management and the Communities of Practice program.


    He also shares some of the work that Rockwell Collins has done to drive Lean into healthcare (including a grant program I worked on).


    Finally, he stressed the importance of not being complacent, always looking for waste and reducing cost of nonconformance, and the strive for continuous improvement. I also share my thoughts on what happened to the Lean program when Kelly Ortberg (now the Boeing CEO and President) took over for Clay in 2013.


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


    Additional Links

    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/⁠⁠⁠⁠⁠

    Sep 08, 202415:29
    E108: The Lean Journey at Rockwell Collins with Clay Jones - Part 5

    E108: The Lean Journey at Rockwell Collins with Clay Jones - Part 5

    This is part 5 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 the 5 lessons learned from the first 8 years of the Lean journey at Rockwell Collins (1998 to 2006).


    1. Senior Leadership alignment
    2. Managing change and resistance
    3. Course correction when needed
    4. Implement Value Stream Mapping first
    5. Ask for help


    "If leadership isn't driving your Lean transformation, don't even start. It's like teaching a pig to talk. You're wasting your time, and you're annoying the pig" - Clay Jones


    He shares some impressive results that were partly due to Lean implementation. Stock price increase of 260%, return on investment capital from 21% to 38%, sales almost doubled from $1.8B to $3.5B, net income over 80%, both business units over 18% operating margin, along with the traditional improvements to on-time delivery, customer acceptance (quality) and sales per employee.


    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/⁠⁠⁠⁠⁠

    Sep 05, 202412:29
    E107: The Lean Journey at Rockwell Collins with Clay Jones - Part 4

    E107: The Lean Journey at Rockwell Collins with Clay Jones - Part 4

    This is part 4 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 expanded on the Core Process Optimization efforts to move to Lifecycle Value Stream Management. This allowed them to address the wastes in the handoffs between major processes. The VSM roles required them to change their roles, metrics, behaviors and cost allocations.


    "Lean is a journey, not a destination" - Clay Jones


    He also shares how they expanded Lean into innovation and creative processes like Engineering, Design and Development and Research. This broke the stereotype that Lean was only for manufacturing. The standardization of these major processes helped bring some consistency and efficiency to how a product was proposed, funded, managed, designed, transitioned and supported.


    He also reiterated the importance of knowledge management in capture information and disseminating it across the organizations and value streams.


    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/⁠⁠⁠⁠⁠⁠

    Sep 02, 202417:57
    E106: The Lean Journey at Rockwell Collins with Clay Jones - Part 3

    E106: The Lean Journey at Rockwell Collins with Clay Jones - Part 3

    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/⁠⁠⁠⁠

    Jun 29, 202411:56
    E105: The Lean Journey at Rockwell Collins with Clay Jones - Part 2

    E105: The Lean Journey at Rockwell Collins with Clay Jones - Part 2

    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/⁠⁠⁠


    Jun 24, 202412:17
    E104: The Lean Journey at Rockwell Collins with Clay Jones - Part 1

    E104: The Lean Journey at Rockwell Collins with Clay Jones - Part 1

    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/⁠⁠

    May 18, 202408:33
    E103: How to gather data before starting an improvement project

    E103: How to gather data before starting an improvement project

    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/⁠

    May 05, 202407:01
    E102: How Green Belt training can benefit you personally and your organization

    E102: How Green Belt training can benefit you personally and your organization

    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/


    Apr 25, 202405:07
    E101: My thoughts on former Boeing Quality Manager (John Barnett) interview prior to death

    E101: My thoughts on former Boeing Quality Manager (John Barnett) interview prior to death

    In episode 101, I share an interview clip from John Barnett, former Boeing Quality Manager, as he discusses the culture of quality that might explain the recent airline issues. He was found dead while he was giving a deposition about his former company, but I don't go into those details. I wanted to share my insights about a comment he made that inspection is non-value added, and how I think it has been misunderstood.


    Inspection is non-value added, but that doesn't mean you stop inspecting. You need to remove the causes for the inspection before you can even consider removing or reducing inspection or test.


    Links
    Mar 27, 202407:50
    E100: How 6 M's and Fishbone (Ishikawa) or Cause and Effect Diagrams Can Help Reduce Water Consumption Usage in your Company

    E100: How 6 M's and Fishbone (Ishikawa) or Cause and Effect Diagrams Can Help Reduce Water Consumption Usage in your Company

    In episode 100, I share a segment of a Lean Six Sigma Green Belt training course I conducted, where I went into details about the Fishbone Diagram and the 6 M's, and I thought you might find it useful.

    When you are trying to uncover possible causes of a problem, using the 6 M's with a Fishbone Diagram is a great way to enhance your team brainstorming, and methodically narrow down the causes through a process of elimination.

    I've also posted a video of the slides I presented, if you want to see the graphics and gain more insights from what I shared.


    Links
    Mar 05, 202407:08
    E99: Excerpt from the book, "Lean Six Sigma for Good - Lessons from the Gemba (Volume 1)"

    E99: Excerpt from the book, "Lean Six Sigma for Good - Lessons from the Gemba (Volume 1)"

    In episode 97, we released an excerpt by Elisabeth Swan from "Lean Six Sigma for Good: Lessons from the Gemba (Volume 1)"

    This is an excerpt from the audiobook version Volume 1.

    I share the story of running a small nonprofit organization in Portland, called Recycling Advocates (now called Waste-free Advocates). We created a fundraiser conference called Zero Waste Conference, to promote the reduction of items going to the landfill.

    I was able to incorporate some Lean and Six Sigma principles to the event planning to prevent issues like parking confusion, sign-in delays, seating charts, predicting show up rates, and much more. The entire chapter requires the purchase of the book, but remember that the proceeds from the book sales supports the nonprofit organizations selected by each of the 8 chapter authors.

    Links
    Feb 20, 202406:57
    E98: Lean Six Sigma training and Coaching Program Case Studies

    E98: Lean Six Sigma training and Coaching Program Case Studies

    In this podcast, I expand on Podcast #96, where I talked about the questions to consider in a training and coaching program.

    I go through 6 different case studies of customized training and coaching programs I've helped develop with clients to meet their specific needs, and how the payback on training is often as short as a few months!

    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


    Links

    Feb 13, 202411:57
    E97: Excerpt from the book, "Lean Six Sigma for Good - Lessons from the Gemba (Volume 2)"

    E97: Excerpt from the book, "Lean Six Sigma for Good - Lessons from the Gemba (Volume 2)"

    This is an excerpt from the audiobook version of "Lean Six Sigma for Good: Lessons from the Gemba (Volume 2)"
    Elisabeth Swan shares the story of volunteering with the Cape Cod Childcare Development nonprofit organization. She discusses getting a call from the CEO to help the organization utilize more Lean Six Sigma Green Belt skills and methods within the organization.
    In one of the examples highlighted in her chapter, she shares how they reviewed their expenses and processes, and managed to update the ordering process, consolidate vendors, reduce the number of steps involved in getting supplies to the people who needed them, all while ensuring the Finance Department received the right info to pay the bills. The savings from the monthly cellphone bill, combined with switching to a new vendor, was enough to afford the mortgage for the building to house the new Head Start program.
    Proceeds from the book purchase supports the nonprofit organizations selected by each of the 8 chapter authors.

    Links
    Feb 07, 202406:44
    E96: What is the best option for effective Lean Six Sigma training and coaching?

    E96: What is the best option for effective Lean Six Sigma training and coaching?

    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


    Links

    Feb 02, 202412:21
    E95: Hypothesis Testing Basics - Can James Bond tell the difference between a shaken or stirred martini?

    E95: Hypothesis Testing Basics - Can James Bond tell the difference between a shaken or stirred martini?

    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


    Links

    Jan 23, 202404:37
    E94: Interested in a Free "Lean at Home" Coaching Program?

    E94: Interested in a Free "Lean at Home" Coaching Program?

    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)


    Jan 08, 202403:38