Lean‘s Role in Labor Shortages and the Supply Chain

Electrification has given rise to new American automotive ventures such as Tesla, Rivian, and Lucid Motors. Aside from the powertrain, these companies are innovating the driving experience through breakthrough performance and by deeply integrating software into vehicle architecture.   These disruptions demonstrate exciting possibilities but raise a challenge: how can companies innovate while upholding customer expectations of quality?  In an episode of the WLEI podcast, LEI sat down with industry veteran and Lucid Motors’ Vice President of Quality Jeri Ford to explore that question. Jeri has over 30 years of experience in the automotive industry, having held leadership roles at Ford and Rivian before joining Lucid.  The conversation explores:  How product development impacts quality downstream in manufacturing and supply chain.  The importance of collaboration between functions to achieve quality objectives.  Balancing speed and quality in bringing new vehicles to market.  Adapting processes for the integration of software and hardware in modern vehicles.  Building alignment and a culture of quality in a startup environment.  Listen to gain these insights and learn about the challenges facing the automotive industry in an era of technological change.   Be among the first to get the latest insights from LEI’s Lean Product and Process Development (LPPD) thought leaders and practitioners. This article was delivered to subscribers of The Design Brief, LEI’s newsletter devoted to improving organizations’ innovation capability. It is the fourth of five in a series on quality entitled “Whatever Happened to Quality First? Rethinking Product Development the Wake of Recalls and Catastrophic Failures.” Click to read the first, second, and third articles.

In this episode of the WLEI podcast, LEI speaks with Emily Swaney and Alli Kulp from OhioHealth. Emily is the senior director of OhioHealth's lean promotion office, leading the organization's continuous improvement team. Alli is a senior advisor in the lean promotion office and previously worked as a registered nurse. In our discussion, we explore:  The lean journey at OhioHealth since 2006 and their goal of creating a culture of 35,000 problem solvers.  OhioHealth's strategic goal deployment process and how they cascade goals throughout such a large healthcare system.  How lean daily management and problem solving are implemented at the frontlines through huddles and visual boards.  Tools OhioHealth has developed to assess lean leadership behaviors and the management system to drive progress.  Emily and Alli will lead a learning session on creating leadership assessment tools to foster development at the Lean Summit on March 19-20 in Carlsbad, CA. 

In this episode of the WLEI podcast, we speak with Dennis Wade from Oakland University and Lisa Eshbach, PhD from Ferris State University. They share their universities' programs that provide hands-on lean learning experiences for students through collaboration with industry partners.  In our discussion, we explore:  The backgrounds and roles of Dennis Wade and Lisa Eshbach in academia and their work connecting students to real-world lean projects.  The models used at Ferris State University and Oakland University for experiential learning projects, including course-based projects and paid internships.  The impact of these programs on students' development of lean skills and tools, as well as skills like collaboration and problem-solving.  Examples of projects undertaken by students, such as a kanban system for an eye clinic supply room and creating a food pickup process for a university food pantry.  Dennis and Lisa will lead a learning session on connecting industry to academia at the Lean Summit on March 19-20 in Carlsbad, CA. To contribute to the James P. Womack Scholarship, which funds student internships at Oakland University, email us at [email protected]. Click here to read case studies from past student projects funded by the scholarship.

In this episode of the WLEI Podcast, our guests are Jennifer Trask and Brittney Heatherington from MillerKnoll. Trask is the Director of the MillerKnoll Performance System (HMPS) for business processes and dealer network, while Heatherington is a continuous improvement coach for the dealer network.  In our discussion, we explore:  MillerKnoll’s methodical approach to people development.  How MillerKnoll has built a culture of operational excellence throughout its value stream from its factories to its dealers.  How MillerKnoll successfully engages dealers in problem-solving by coaching at the gemba. The importance of approaching problems situationally versus applying a fixed solution.

In this episode of the WLEI podcast, LEI speaks with Billy Taylor, former operations executive at Goodyear Tire & Rubber Company. He is now President of LinkedXL and author of The Winning Link: a Proven Process to Define, Align, and Execute Strategy at Every Level.  In our discussion, we explore: Billy’s career journey from third shift supervisor to director of North American operations for Goodyear. How Billy led a transformation of one of Goodyear’s worst-performing plants through instituting a few core principles: deliberate clarity, defined ownership, deliberate practice, and trust.  Billy’s approach to scaling a management system from a single plant to multiple plants across North America through intense collaboration with plant leaders.  The current challenges of retaining employees due to changing workforce mindsets post-COVID and how to re-engage workers.

In this episode of the WLEI podcast, LEI's guests are Mary Nell Egan and Lisa Karam from MassMutual, a leading insurance company. Egan and Karam delve into the intricacies of transformation in a traditionally cautious, large organization. In our discussion, we explore several key themes: MassMutual’s evolution from a tool-centric to a customer-value approach in their lean journey. The methods Egan and Karam used to engage previously disengaged leaders with lean, linking continuous improvement to corporate strategy. The critical role of meeting people where they are in mitigating resistance to change. The significance of resilience in lean transformation.

LEI chats with Frank Paluch, Retired President of Honda R&D Americas, and Lara Harrington, Retired Honda Chief Engineer. Frank and Lara share how Honda utilized Lean Product and Process Development principles to launch successful vehicles like the Honda Passport.  During the conversation we dive into the following:  Understanding Customer Value – As Chief Engineer of the Honda Passport Lara explains how she used rapid prototyping and gathered consumer feedback early in the development process to determine a vehicle design that would appeal to customers and grow Honda’s market share. The Chief Engineer – Frank and Lara reflect on the chief engineer’s role, what makes a great chief engineer, and the matrix organization in which they work. People Development – Comparing hiring in engineering talent versus developing it internally. Future of the Auto Industry – Discussing the industry push toward EVs and contrasting Tesla’s approach to development to Toyota’s.  Special note: Lara and Frank will lead a keynote about Lean Product and Process Development at the Lean Summit in March 2024. To learn more and register, click here.

In this episode of the WLEI Podcast, we speak with Jill Katic and Grace Eovaldi from Barton Malow, a major construction company that has recently seen significant growth. Jill and Grace share how they've been working to foster a culture of problem solving throughout Barton Malow, principally through a program dubbed Lean University.  During the conversation we dive into the following:   Lean Principles and A3 Problem-Solving: Exploring Lean University's five-day training program, which introduces participants to lean principles and the A3 problem-solving method over a three-month period.  Problem Identification and Analysis: How Jill and Grace use the program to help participants identify and dissect problems in their work, guiding them in developing effective countermeasures.  Business and Cultural Results at Barton Mallow: Insights into the tangible business outcomes and cultural shifts experienced by Barton Malow since beginning Lean University.  Lean Thinking and Problem-Solving Skills: The significance of Lean University for organizations seeking to cultivate lean thinking and problem-solving abilities among their employees.  Barton Mallow's Lean Journey: An overview of Barton Malow's experience with Lean University and its role in transforming the company's culture.  Special note: Jill and Grace will lead a learning session about building a problem-solving culture through Lean University at the Lean Summit in March 2024. To learn more and register, click here.

In this episode of the WLEI Podcast, we talk with Fabrice Bernhard and Catherine Chabiron. Fabrice is the co-founder of Theodo, a fast-growing software company, and Catherine is the author of the new book, Learning to Scale at Theodo: Growing a Fast and Resilient Company. Fabrice and Catherine share how Theodo has seamlessly integrated lean thinking into its management system enabling it to grow rapidly while maintaining a customer-first mindset and ship quality software. During the conversation, we dive into: Lean vs. Agile: How Theodo found lean thinking and how it complements agile, while challenging traditional perspectives in the software industry. Quality vs. Speed: Navigating the delicate balance between producing high-quality code and meeting the demands for rapid delivery. Customer Focus: How lean has enhanced Theodo’s customer-centric approach, making it a hallmark of their operations. Learning Organizations: The role of continuous learning in building resilient teams that not only solve technical problems but contribute to organizational growth. People Development: How Theodo leverages problem-solving at the gemba to foster a culture of continuous improvement and employee development. Special note: During the conversation, we mention the book The Toyota Way of Dantotsu Radical Quality Improvement, which Theodo has been using to transform its approach to improving quality.

In this episode of the WLEI Podcast, we speak with Mehmet Gur, Senior Director of Operations Engineering at DHL eCommerce. He has been leading the company's next-generation automation efforts. Since the pandemic, DHL eCommerce – DHL's business-to-consumer unit – has faced dramatic increases in volume. This surge required new automation technology to meet customer demand and heightened expectations regarding delivery speed. Mehmet oversees a large team of technical engineers tasked with meeting this challenge.  During the discussion we touch on:   Lean Thinking and Automation: How Mehmet's team used value-stream mapping to close the gap between automation equipment’s theoretical throughput and actual throughput.   Automation Evaluation: What should organizations consider before investing millions in new technology.  People Development: How to use problem-solving at the gemba to not just solve intractable technical problems but develop engineers.   AI in Distribution: How emerging technologies are revolutionizing logistics for higher throughput and customer satisfaction.  Mehmet will lead a learning session on these themes at the LEI Lean Summit in March 2024. To learn more and take advantage of early registration discounts, visit lean.org/summit. Register by October 31 to save up to $900 on your summit registration.