Lean 911

Hosted by Mark DeLuzio

Business Management Education

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Episodes

Latest episode

Aug 2026

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EN-US

About the show

The Lean 911 Podcast is where you'll have a voice directly from the gemba. Host, Mark DeLuzio, President and CEO of Lean Horizons Consulting and the principal architect of the Danaher Business System, relies on his three decades of lean successes as well as his failures to answer your most challenging questions regarding your lean transformation.

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60 recent

August 19, 202628 min

From Toyota to Danaher to Your Enterprise: Introducing Lean Horizons Academy

What if the Lean lessons that helped shape one of the world’s most respected business systems could be made available to everyone in your organization—anytime, anywhere, and in virtually any language? In this episode of Lean911, we introduce Lean Horizons Academy, a new approach to building practical Lean capability across the enterprise. Lean Horizons Academy is inspired by the original teachings of the Toyota Production System and shaped by the lessons and practices that helped build the Danaher Business System. It transforms decades of real-world Lean experience into an accessible e-learning platform designed not simply to teach Lean concepts, but to help people apply them where the work actually happens. We explore how the Academy helps organizations move beyond traditional, consultant-dependent training by creating a common Lean language and giving employees ongoing access to practical knowledge, tools, and methods. The goal is speed to value—getting proven Lean thinking into the hands of more people, faster, so they can begin solving problems, improving processes, and delivering measurable results. The episode also explores the role of live monthly sessions with Mark, where participants can ask questions, present their real-world challenges, and learn directly from four decades of successful Lean transformations across six continents and dozens of industries. Most importantly, Lean Horizons Academy addresses one of the persistent challenges of Lean transformation: training that shouldn't end when the consultant leaves. The Academy is designed to create a sustainable internal capability that continues developing people long after a workshop, kaizen event, or consulting engagement is over. In this episode, you'll discover: How the teachings of Toyota influenced the development of the Danaher Business System How those lessons have been translated into practical Lean e-learning Why enterprise-wide access can dramatically accelerate Lean capability building How organizations can establish a common Lean language across functions, locations, and countries Why combining on-demand learning with live access to an experienced Lean practitioner creates a powerful development model How Lean Horizons Academy can help organizations move from Lean training to lasting Lean capability Inspired by Toyota. Shaped by the lessons that built the Danaher Business System. Now available to your enterprise. If you're responsible for Lean, Operational Excellence, Continuous Improvement, or enterprise transformation—and you're looking for a faster, more scalable way to develop problem solvers throughout your organization—this episode is for you.

August 3, 202633 min

The Danaher Business System – 12 Things I’d Do Differently

When you build something that stands the test of time, it's tempting to believe you'd do it the same way all over again. But experience has a way of changing your perspective. In this episode, I look back at the creation of the Danaher Business System and share 12 things I would do differently if I were building it today. From placing greater emphasis on management systems over individual tools, to developing stronger problem-solving leaders, eliminating performance reviews, focusing on upstream process improvement, and leading with leading indicators instead of lagging metrics, these are lessons earned through decades of applying and refining DBS. This isn't about second-guessing a successful system—it's about recognizing that even the best operating systems can evolve. If you're building a business system, leading a transformation, or trying to create a culture of continuous improvement, these reflections may help you avoid mistakes I only recognized in hindsight. In this episode, you'll learn: Why management systems matter more than individual improvement tools. The importance of developing leaders who can coach and teach problem-solving. How performance management and organizational structure can either accelerate or hinder improvement. Why upstream thinking, engineering excellence, and leading indicators deserve more attention. Twelve practical lessons I'd apply if I were building the Danaher Business System again. Whether you're a CEO, operating executive, private equity leader, or continuous improvement practitioner, this episode offers a candid look at what experience teaches us after the work is done—and what I'd do differently if I had the opportunity to start over.

July 15, 20261 hr 22 min

Be The Magic: 4 Phases to Transform Your Life with Manish Chauhan

What if the biggest transformation in your life begins with a simple shift in perspective—not from believing life is happening to you, but realizing it is happening through you? In this episode, we explore Be The Magic: 4 Phases to Transform Your Life by Manish Chauhan, a practical and deeply reflective guide that blends timeless spiritual wisdom with modern psychology, neuroscience, and real-life coaching. Together, we'll unpack the book's four transformative phases—Victimhood, Intention, Inspiration, and Awakening—and discover how each stage offers an opportunity to move toward greater clarity, purpose, and inner freedom. We'll also dive into the book's MAGICx framework, which combines Meditation, Affirmation, Gratitude, Inspiration, Compassion, and eXercise into an actionable daily practice. Along the way, we'll explore ideas inspired by vision boards, present-moment awareness, The Work of Byron Katie, the Silva Method, minimalism, surrender, and other powerful approaches to personal growth—all woven together into an accessible roadmap for lasting transformation. Whether you're seeking greater fulfillment in your relationships, career, health, finances, or spiritual life, this conversation will leave you with practical insights, thought-provoking questions, and simple practices you can begin using today. If you're ready to stop waiting for life to change and start becoming the source of that change, this episode is for you. It's time to stop chasing magic—and start being it.

July 1, 202644 min

25th Anniversary Episode: Lean Horizons’ Reflections – The Rise of Lean Theater

As Lean Horizons celebrates its 25th anniversary, founder Mark DeLuzio reflects on a quarter century of transformation work across six continents and dozens of industries. In this special episode, Mark examines the evolution—and in some cases, the dilution—of Lean thinking since the early days of the Toyota Production System's global expansion. How did a management system built on scientific thinking, respect for people, and leadership development become, in many organizations, a collection of tools, certifications, events, and visual displays? When did Lean transformation give way to Lean Theater? Mark explores the "telephone game" effect that has altered Lean's original meaning over multiple generations of practitioners, consultants, academics, trainers, and certification programs. He discusses the rise of credentialism, the commercialization of Lean, the shortage of experienced transformation leaders, and the growing gap between performing Lean activities and achieving real business transformation. Drawing on 25 years of hands-on experience, this episode challenges leaders to ask a difficult question: Are we practicing Lean—or merely performing it? Whether you're a Lean practitioner, executive, consultant, or student of organizational excellence, this candid reflection offers valuable lessons on what has been lost, what still works, and what the future of Lean must look like if it is to remain relevant for the next generation. In This Episode: The evolution of Lean over the last 25 years How TPS principles became diluted through the "telephone game" effect The difference between Lean transformation and Lean Theater Why certifications don't equal capability The commercialization of Lean and its unintended consequences The shortage of experienced transformation leaders Lessons learned from organizations across six continents Why the fundamentals of Lean still matter more than ever The future of Lean doesn't require new tools. It requires rediscovering the principles that made Lean powerful in the first place.

June 15, 202654 min

How Hansei Builds Better Leaders

A CNC machine crashed on the shop floor. Nathan Corliss walked out as a young supervisor, angry and ready to blame the operator. What happened next became one of the most important leadership lessons of his career. Mark DeLuzio and Nathan talk about the moment that forced Nathan to confront his own behavior as a leader, and how the scars on his knuckles became a permanent reminder to pause, reflect, and lead differently. The conversation centers on hansei, the Lean practice of honest self-reflection, and why it matters when pressure is high, mistakes are visible, and people are watching how leaders respond. You'll hear how one shop floor incident connects to emotional intelligence, respect for people, Kaizen report-outs, after-action reviews, standard work, compliance, and the danger of fear-based leadership. For Lean leaders, CI managers, plant managers, and executives, this episode is a practical reminder that culture is shaped in the moments when things go wrong. The real test is not whether leaders know the right Lean language. It is whether they can own their mistakes, protect trust, and help people improve without shutting them down.

June 1, 202626 min

Replay: Standard Work

This is an unedited replay of a previous Lean 911 episode, originally published on January 13, 2023. We're bringing it back because the issue still causes Lean transformations to stall, drift, or flatline. One of the most misunderstood parts of Lean, Standard Work, is often dismissed as unnecessary. So many companies contend that they are "doing" Lean, but leave Standard Work by the wayside. In this episode, you'll learn the answers to the most perplexing questions, notions, and beliefs regarding Standard Work, which is a key component of the Toyota Production System.

May 15, 202648 min

The Six Sigma Hysteria

In this episode, we dive into the rise, dominance, and controversy surrounding Six Sigma — the corporate improvement system that promised near-perfect quality and became a management obsession across America. From Motorola's statistical revolution to Jack Welch's aggressive rollout at General Electric, Six Sigma evolved from a useful quality tool into what some critics call a full-blown corporate ideology. Drawing from Mark DeLuzio's provocative essay "The Six Sigma Hysteria," we explore why many Lean practitioners believed Six Sigma created more bureaucracy than breakthrough innovation. We unpack the clash between Lean thinking and Six Sigma methodology, the explosion of belt certifications and consulting culture, and the argument that companies became obsessed with measuring defects while ignoring waste, flow, and human creativity. Along the way, we examine real-world stories from Toyota, Danaher, and GE, and from factory floors where frontline employees solved problems that data alone could not. We also ask a bigger question: Are modern businesses repeating the same mistake today with AI, Agile, and productivity frameworks? This episode is about more than Six Sigma. It's about the danger of turning tools into religion — and what happens when companies mistake methodology for culture.

May 1, 202647 min

Your Machines Are Lying to You, and So Are Your Equipment Vendors – The Hidden Waste Most Manufacturing Engineers Ignore

Manufacturing Engineers pride themselves on precision, but what if the biggest waste is hiding in plain sight—inside the equipment itself? In this episode, we challenge the status quo: excess feeds, slow speeds, and bloated cycle times that no one questions. Even worse, capital equipment is often purchased without alignment to Lean principles—locking in inefficiency for years. Learn how to look at Capital Equipment from a Lean lens…you will find out that equipment vendors are not your friend! We’ll break down how this happens, why it persists, and what engineers should be doing instead. If your machines are running, but not improving, this episode is for you.

April 15, 20261 hr 10 min

What a Fighter Pilot Can Teach You About Selling Lean Value – with Randy Fitzhugh

In this powerful episode of Lean 911, Mark DeLuzio sits down with former Air Force fighter pilot and Danaher sales leader Randy Fitzhugh to unpack the real science behind value selling and why most organizations get it wrong. Drawing from his elite military background and executive experience, Randy reveals how sales is a disciplined, repeatable process. Together, they break down the four pillars of value selling: qualifying opportunities, monetizing value, pre-call planning, and time & territory management. You'll hear eye-opening stories, from cockpit checklists to multimillion-dollar deals, that show why process, preparation, and deep customer understanding outperform charisma every time. This episode dives into: Why most sales teams think they sell value but actually don't How to monetize quality, delivery, and lead-time improvements The hidden cost of treating products like commodities Why checklists (yes, like pilots use) can transform your sales performance How small improvements in sales activity can drive massive revenue gains The critical role of lean thinking in commercial excellence "You don't get what you expect. You get what you inspect." Stop selling features. Start selling value, systematically.

April 1, 202633 min

Standards Written in Blood – There May Be No Second Chance

Lean management teaches that standards are the foundation of safety, quality, and improvement . In aviation, those standards take the form of checklists, redundancies, procedures, and strict cockpit protocols designed to prevent human error. In this episode, we examine the tragic aircraft accident that claimed the life of Greg Biffle and his family , and what it reveals about the danger of ignoring established standards. Reports indicate that critical procedures were bypassed—checklists weren't followed, and an unqualified individual was allowed into the cockpit. In aviation, such deviations can quickly turn routine operations into a catastrophe. Lean organizations understand this principle deeply. Standard work exists not to restrict people, but to protect them . It ensures that critical steps are followed every time, preventing variation that can lead to defects, injuries, or worse. This episode explores how aviation and Lean thinking share the same core truth: Standards are written from experience, and ignoring them removes the safeguards that keep systems safe. Whether in manufacturing, healthcare, aviation, or leadership, the lesson is clear— discipline in following standard work is what makes improvement possible and prevents tragedy.