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PODCAST

Lean 911

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.

business management

All Episodes

00:16:56

How Do You Price Your Product?

Lean 911 ·

2025/11/01

Mark DeLuzio discusses the dangers of cost-based pricing as well as the various issues encountered when doing so. He introduces the merits of market-based pricing instead.

en-US

00:14:18

Stop Measuring Productivity

Lean 911 ·

2025/10/15

Mark DeLuzio discusses the dangers of focusing on the lagging indicator of productivity and suggests we turn our attention towards improving our processes, which will, in turn, drive improved productivity.

en-US

00:43:59

Lessons from the Danaher Business System Office III –...

Lean 911 ·

2025/09/15

Mark DeLuzio discusses the errors made when architecting the Danaher Business System and the things he would do differently today.

en-US

00:43:17

Lessons from the Danaher Business System Office II –...

Lean 911 ·

2025/09/01

A lean office can either accelerate transformation or quietly undermine it. The difference often comes down to trust, leadership alignment, and a clear sense of purpose. Drawing on his time as the architect of the Danaher Business System, Mark shares hard-earned lessons about what makes a lean office succeed and where so many stumble.From CEOs treating their lean teams as spies to audits that destroy credibility, he explains the traps to avoid and the principles that matter. You’ll hear why

en-US

00:38:09

Lessons from the Danaher Business System Office I –...

Lean 911 ·

2025/08/18

Many Lean transformations commence without understanding why, and the communications to employees are poor or nonexistent. Mark DeLuzio talks about this failure mode and why it is essential to answer the question, “What’s in it for me?”

en-US

00:31:53

How Compensation Systems Can Kill a Lean Transformation

Lean 911 ·

2025/07/15

If your Lean transformation feels like it's stuck, your compensation system might be part of the problem. In this episode, Mark tackles a question from Finland about how incentives influence behavior, often in ways that completely undercut Lean principles.He shares how traditional pay structures and metrics, especially those tied to cost and output, often reward the wrong actions. You'll hear examples from the shop floor to the C-suite, including a mining company that saved money on parts but

en-US

00:47:17

Why the Danaher Business System Was Successful – The...

Lean 911 ·

2025/07/01

Mark DeLuzio discusses the intangibles that made all the difference to the success of the Danaher Business System. He also discussed the main ingredients of DBS, the 5Ps: Purpose, Principles, People, Plan, Process.

en-US

00:29:38

The Problem with OEE and Absorption Accounting

Lean 911 ·

2025/06/15

Some metrics were never meant to survive in a Lean world. OEE and absorption accounting might sound smart on paper, but they push the exact behaviors that wreck flow, bury quality issues, and inflate inventory. The result? A system that looks efficient but delivers chaos.Mark DeLuzio breaks down how these outdated measures keep companies locked in batch production and bad habits. He shares firsthand stories from the factory floor and the boardroom, including a jaw-dropping moment with a CFO who

en-US

00:13:57

Why Don’t Your Leaders Listen to You?

Lean 911 ·

2025/05/01

In this episode, Mark DeLuzio talks about why Lean/CI people are not being listened to and gives sage advice as to how to reverse this trend.

en-US

00:28:49

Death by Point Kaizen – Why You Need Kaikaku

Lean 911 ·

2025/04/01

You will never transform your company by point kaizen alone. Learn why traditional Japanese consultants were not enough in order to propel Danaher into a space all by themselves. Kaikaku (radical change) was a hallmark of Danaher’s Strategy Deployment process.

en-US

00:52:32

Jerry Wright – Book Review: “The Insanity Trap – What...

Lean 911 ·

2025/02/01

Mark talks with Jerry Wright on his new book about the ills of MRP. Jerry talks about his experience of seeing failure after failure with companies trying to perfect MRP. He argues that a Lean Transformation is impossible if MRP is used as the primary resource planning tool. MRP was first introduced in 1964 and despite its failures, is still the tool of choice for so many companies today.

en-US

00:58:10

Griselda Abousleman – The Power of Optimism

Lean 911 ·

2025/01/15

Mark talks with an esteemed Lean colleague, Griselda Abousleman, whose life story should be an inspiration to all minority women, as well as to all of us who are struggling to make it in this world. Her incredible story is chronicled in her newly released book, “From the Border to the Boardroom.” Griselda talks about her upbringing in a Texas border town and her tenacity to refuse to give in when others told her she cannot succeed. Her rise from the border town of Brownsville, Texas, to an Ivy

en-US

00:12:43

The Productivity Hysteria

Lean 911 ·

2024/12/15

Are you focusing on productivity as your barometer of Lean improvements? Mark DeLuzio discusses why this approach may be leading your Lean transformation into a brick wall.

en-US

00:17:01

Death by Lean Audits

Lean 911 ·

2024/12/01

Have you ever wondered why a supplier is auditing their "customer?" Mark discusses the ills of Lean Audits and the destructive culture created by those executing these audits.

en-US

01:07:14

The Poison of Metrics – With Jon Boucher

Lean 911 ·

2024/10/01

Like many poisons, they initially taste good. However, over the course of time, the poison will be your ultimate demise. Mark and Jon talk about how our metrics drive behaviors that fly in the face of Lean principles. Most metrics today do little to truly solve a problem. Traditional accounting, Gemba Boards, and standard KPIs need to be carefully evaluated to ensure they are congruent with your Lean transformation.

en-US

01:09:59

The 7 Flows – With Jon Boucher

Lean 911 ·

2024/09/15

Learn about the 7 Flows of Manufacturing as taught by our Sensei Chihiro Nakao of Shingijutsu. Jon takes us through The 7 Flows, which are easy to understand. However, not all that easy to implement. These concepts are a must if you are to call your operations “Lean.”

en-US

00:21:05

Why The Theory of Constraints (TOC) Was Not Included...

Lean 911 ·

2024/09/01

Mark discusses why TOC was not included in the framework of DBS and how TOC is in conflict with fundamental Lean principles. In the final analysis, it was determined that TOC offered nothing unique when compared to Lean and had the potential to drive the wrong behaviors while creating mass confusion amongst Danaher companies.

en-US

01:27:34

The Early Days at Danaher with Art Byrne

Lean 911 ·

2024/08/15

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO, about the early days at Danaher. Learn that it was more than the factory floor that had to change…more importantly, it was the mindset of Danaher’s leadership. Art and Mark discuss the history of Jake Brake and Jacobs Chuck, the two early adopters of the Toyota Productions System, as led by the disciples of Taiichi Ohno, Shingijutsu Consulting, LTD. Little did Art know that we would be setting the stage for the adoption of Lean in

en-US

01:08:06

How to Create a Lean Culture – With Art Byrne

Lean 911 ·

2024/08/01

Mark talks with Art Byrne, former Danaher executive and Wiremold CEO. Art talks about the elements to create a Lean culture. In plain words, Art states that culture is defined as: “Just the way we do things here.” As you listen to Art, who pioneered one of the most successful Lean transformations at Wiremold, you will see the emphasis he places on people and his strict advice as to the changes a CEO needs to make in order to successfully execute a Lean transformation.

en-US

00:45:43

Mixed Model Production II – Implementation

Lean 911 ·

2024/06/15

Kevin Mathis, Managing Director of Lean Horizons Consulting, talks about how he created the first Mixed Model Production cell in Danaher. In this episode, Kevin discusses how to implement a mixed model cell as well as how it all relates to the fundamentals of the Toyota Production System, specifically, JIT, Standard Work, Heijunka, Kaizen and Jidoka.

en-US

52 results

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