Why Did Operational Excellence Implementations Fail in 2024?

If you’re a consultant, coach, or thought leader who relies on reputation, referrals, or content to win business, AI is already changing how people find and trust experts. In this episode, Antonio Rothenbach sits down with Andi Simon, corporate anthropologist, CEO of Simon Associates Management Consultants, and host of On the Brink with Andi Simon, to explore how AI search is reshaping visibility, credibility, and authority. Search is no longer just about ranking on Google. Today, tools like ChatGPT, Copilot, and Perplexity summarize, recommend, and sometimes decide who the “preferred expert” is before a prospect ever clicks a link. This conversation dives into: How AI search actually works today Why content alone is no longer enough How AI decides who to trust and cite The human side of AI adoption and resistance What consultants can do now to stay discoverable and relevant This episode is especially relevant for consultants, advisors, and leaders who want to future-proof their visibility as AI becomes the front door to expertise. Key Topics & Timestamps (00:00) Why AI is changing how trust and credibility are built (01:10) Meet Andi Simon and her background as a corporate anthropologist (05:00) Why humans resist change and how that affects AI adoption (08:30) How AI search differs from traditional Google SEO (11:00) How Andi uses AI as a collaborator, not a replacement (15:00) What makes content discoverable by AI tools (18:30) FAQs, authority signals, and AI-driven visibility (22:00) A simple way to test what AI already knows about you (26:00) Content repurposing as an AI visibility strategy (30:00) Why leadership and culture determine AI success (36:00) Final advice for consultants navigating AI-driven change About the Guest Andi Simon is a corporate anthropologist, CEO of Simon Associates Management Consultants, award-winning author, speaker, and host of the podcast On the Brink with Andi Simon. With over two decades of experience helping organizations adapt to major shifts, Andi brings a unique lens to AI adoption by focusing on human behavior, beliefs, rituals, and leadership. Her work helps leaders and organizations see what’s often right in front of them so they can move forward with clarity and confidence. About the Host Antonio Rothenbach is the host of The AI Agency Journey and the founder behind Ibero AI and Belt Course. He works with consultants, leaders, and organizations at the intersection of AI, Operational Excellence, and leadership to turn AI from a buzzword into practical business impact. Resources & Links Andi Simon on LinkedIn Simon Associates Management Consultants: https://simonassociates.net  Andi Simon’s books, podcast, and speaking: https://andisimon.com  Antonio Rothenbach on LinkedIn: https://www.linkedin.com/in/antonio-rothenbach-99685110/  Subscribe & Follow If you enjoyed this episode, subscribe to The AI Agency Journey on your favorite podcast platform and follow along for more conversations with consultants, operators, and leaders navigating AI-driven change. New episodes explore real lessons learned at the intersection of AI, leadership, and operational excellence.

Guest: Jess Orr – ex-Toyota engineer, former corporate OpEx leader and VP of Operations Summary: In this episode, Jess and Antonio connect the dots between Operational Excellence and Artificial Intelligence. Jess shares what she learned at Toyota, in a successful divisional OpEx transformation, in a failed enterprise-wide rollout, and later as VP of Operations — and how all of that experience shapes how she thinks about AI today. The core message: OpEx and CI professionals are uniquely positioned to lead AI efforts because they already know how to define problems, find constraints, and drive cultural change. Starting with tools — whether it’s Lean tools or AI tools — almost always fails. Antonio then introduces the concept of AI Business Audits as a structured way for consultants to partner with clients, identify their real bottlenecks, and use AI for brainstorming, solution design, and ROI modeling, instead of jumping blindly into “doing AI.” 3–5 Key Takeaways: Toyota vs everyone else: Toyota embedded continuous improvement in everyone’s job, while many companies try to bolt on CI through tools without a culture to sustain it. Tools don’t fix culture. Rolling out 5S, DMS, or even AI tools without leadership alignment and clear “why” leads to shallow adoption and failed transformations. Consultants as capability builders, not crutches. External consultants are most valuable when they build internal capability and mentor internal champions — not when they become permanent life support. OpEx + AI is a natural pairing. CI practitioners already know how to map value streams, find constraints, and run structured problem solving. AI simply gives them superpowers if used correctly. AI Business Audits are the bridge. Starting from constraints and problems, then using AI to explore options and quantify ROI, is a far better path than “Let’s try some AI tools and see what happens.” Links: Book an AI Business Audit with Antonio / Ibero AI:  https://calendar.app.google/HahxbRKD77n3KiU9A Connect with Jess on LinkedIn:  https://www.linkedin.com/in/jessorr/ Connect with Antonio on LinkedIn:  www.linkedin.com/in/antonio-rothenbach-99685110 Podcast show on YouTube:  https://youtube.com/playlist?list=PLyVgVZd7jUlpcp4mwtNMbXlv8D_8CB3Ch&si=JI3iG6LZp6gQT7Va

Guest: Dave Rosenberg, Principal at Locked On Leadership Summary: In this episode, Dave shares 35+ years of leadership experience—from Navy officer to company president to leadership coach—and how his Radical Accountability framework helps leaders turn disengaged employees into energized contributors. Together, Antonio and Dave explore how AI tools can complement human coaching, fostering self-awareness, delegation, and engagement. Top 3 Takeaways: Leadership gaps = business gaps. Most operational problems stem from cultural and leadership breakdowns. Radical Accountability drives engagement. Clear systems, communication, and shared purpose unlock higher performance. AI as a coaching ally. Used right, AI helps structure thinking and reflection without replacing intuition or empathy. Quote: “My mission is to help every team member say ‘Thank God It’s Monday.’ That’s when you know leadership is working.”   🗓️ Book a 20-min AI Business Audit : https://calendar.app.google/y4z3RGmK2n2KHfzMA

Host: Antonio Rothenbach, Founder & CEO of Ibero AI Guest: Donna Huntley, CEO of People Pulse Ventures Episode Summary: Fear is one of the biggest barriers to AI adoption — and it’s costing companies growth, innovation, and talent. In this conversation, Antonio and Donna break down how to replace fear with confidence through training, governance, and culture. Donna shares stories from her 20+ years in HR consulting — from early digital hiring systems to leading change at Accenture — and offers practical strategies for leaders who want to bring AI into their organizations without losing the human touch.   Connect with Donna: - www.peoplepulseventures.com - Call/text: 803-836-0306   Connect with Antonio: - www.linkedin.com/in/antonio-rothenbach-99685110/   Subscribe to The AI Agency Journey Podcast: - Spotify: https://open.spotify.com/show/0lXZkUqO2RIkN7vTO1C2p7?si=25f17d152e6040e7 - Apple Podcasts: https://podcasts.apple.com/us/podcast/the-ai-agency-journey/id1788580727

Read the blog article here: https://www.beltcourse.com/blog/linkedin-growth-that-lands-ai-opex-ci-clients-without-gaming-the-algorithm A detailed guide for Artificial Intelligence (AI), Operational Excellence (OpEx), and Continuous Improvement (CI) consultants on leveraging LinkedIn for client acquisition. It outlines a strategic playbook for creating content that resonates with B2B buyers, emphasizing observable signals for distribution rather than trying to outsmart the algorithm. Key areas covered include optimizing post engagement, crafting impactful content formats, and using LinkedIn's native features to maximize reach. The guide also offers practical advice on posting frequency, avoiding common mistakes, and measuring success through relevant metrics, aiming to help consultants generate qualified leads and conversations.

This episode explores the evolving landscape of continuous improvement leadership and identifies significant skill deficiencies across various sectors. It highlights universal gaps in areas like digital transformation leadership and data analytics, while also detailing industry-specific needs for Industrial Advanced (e.g., automotive, medical devices), Industrial (e.g., pharmaceuticals, food & beverage), and Supply Chain professionals. The analysis proposes tailored coaching programs designed to address these gaps, emphasizing technical, leadership, and strategic competencies.    Coaching Programs for Industrial Advanced Digital Transformation:  Transition to lead a Digital and Artificial Intelligence Transformation from start to finish!  Click here to learn more. DMAIC and AI-Assisted Process Improvement:  Master the DMAIC methodology and AI-enhanced analytics to become the go-to process improvement leader!  Click here to learn more. Innovation Launch Mastery: Master FMEA, Digital Twins, and Agile Innovation to become the launch leader who delivers on time, on budget, and exceeds expectations!   Click here to learn more. Coaching Programs for Industrial Achieving Stability (Focus on Stability and Sustainment):  Solidify your teams' ability to sustain improvements with the use of control plans, proper communication, report-outs, Layered Audits, and more!  Click here to learn more. A3 Problem-Solving (RCA, First Projects in your A3):  lead projects, using A3 Problem-Solving and Job-Specific pathways dependent on your opportunities!  Click here to learn more. Lean Leader:  Start using Lean methodologies and tools (VSM, 5S, QCO, TPM, DMS, Kaizen, JIT, Poke Yoke, etc.) to transform your value streams.  Click here to learn more. Kaizen Leader:  Be fully prepared to lead a Kaizen Event to make sustainable improvements quickly, without wasted efforts!  Click here to learn more.     Coaching Programs for Supply Chain Digital Transformation:  Transition to lead a Digital and Artificial Intelligence Transformation from start to finish!  Click here to learn more. Supply Chain Management (SCM) Leader:  Achieve stability and advance into Proactive Supply Chain Management This Year!  Click here to learn more. Strategic Planning (Hoshin Kanri + Value Stream Mapping, Bottleneck, OEE & Loss Analysis):  Build your Strategic Plans, aligning goals with resources, without taking years to get better at it!  Click here to learn more.

Read the source article here:  https://www.beltcourse.com/blog/the-ci-manager-crisis-why-ci-leaders-struggle-and-why-hiring-a-ci-manager-from-outside-isn-t-the-solution   Continuous Improvement (CI) Managers frequently struggle due to issues like team resistance, role ambiguity, and a lack of impact. The author contends that hiring externally is a detrimental solution because it leads to slow ramp-up times, higher costs, and internal team demoralization. Instead, the article advocates for developing internal talent to fill CI Manager roles, emphasizing that individuals already familiar with the organization's culture and processes are better positioned for success. This internal development approach fosters quicker integration and boosts overall team morale and retention, ultimately leading to more effective and sustainable CI initiatives.

Read the article that was the source of this discussion here:  https://www.beltcourse.com/blog/why-do-operational-excellence-implementations-fail-in-2024   Learn a better way at www.beltcourse.com   This episode explores why Operational Excellence (OpEx) implementations often fail, identifying a primary issue as a lack of comprehensive capability building rather than solely blaming leadership. It acknowledges the challenges faced by OpEx professionals in providing sufficient training to everyone and examines existing solutions like consultants and outside training providers, highlighting their limitations in cost, practicality, and scope. The author suggests a need for different solutions that leverage the expertise of multiple individuals and provide a structured roadmap for training the right people effectively, with the goal of significantly reducing OpEx failure rates.

For a longer list of specific easy and impactful office project examples for each of the most common areas and functions, find it by clicking here!     Office & Service Companies – 10 Project Ideas per area Office Functions within Industrial Organizations – 10 Project Ideas per function   The application of Lean in Offices and Service environments is slightly different... learn more about it here...  https://www.beltcourse.com/lean-in-offices-and-services-one-pager   This episode explores numerous project ideas for applying Lean methodologies, Operational Excellence principles, and Artificial Intelligence within office and service environments. It categorizes these examples into ten distinct areas for both office and service companies, such as legal, accounting, and marketing, and ten specific office functions within industrial organizations, including engineering, finance, and HR. For each area and function, targeted project concepts are discussed, offering concrete starting points for continuous improvement initiatives. Many examples explicitly mention specific tools like A3 problem-solving, value stream mapping, FMEA, and potential AI applications like automation and prediction. The episode aims to inspire practical application of these concepts for enhancing efficiency and effectiveness in various organizational settings.

Lean and Operational Excellence (OpEx) methodologies, traditionally associated with manufacturing, are highly applicable and beneficial in office and service environments. These principles address common workplace inefficiencies such as lengthy approval processes and redundant tasks by treating offices as "invisible factories" with improvable workflows. By employing tools like process mapping, root cause analysis, and AI-powered insights, organizations can reduce errors, eliminate low-value work, and empower employees.   You have to equips teams with practical skills to implement these improvements, offering real-world examples of successful transformations across various industries. Ultimately, applying Lean and OpEx, often enhanced by AI, leads to significant gains in efficiency, customer satisfaction, and overall organizational performance in non-manufacturing settings.   Join the Office Operational Excellence Program today. ✔️ Explore the Program📄 Download the Full Program Outline Lean isn’t just for factories anymore—let’s bring it to the office, where it belongs.   The application of Lean in Offices and Service environments is slightly different... learn more about it here...  https://www.beltcourse.com/lean-in-offices-and-services-one-pager   For a longer list of specific easy and impactful office project examples for each of the most common areas and functions, find it by clicking here!     Office & Service Companies – 10 Project Ideas per area Office Functions within Industrial Organizations – 10 Project Ideas per function   Get coached by our AI Assistant OpEx Coach!  Link: https://www.beltcourse.com/opex-coaches-ai-assistant