The Lean Solutions Podcast

What You’ll Learn in This Episode:In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent dive into the real starting point of Industry 4.0—shifting from “proof of concept” to “proof of value.”You’ll learn why simply collecting machine data isn’t enough, and how to tie that data directly to financial outcomes that matter to leadership. The conversation breaks down practical first steps like digitizing paper processes, improving network infrastructure, and starting small with one machine or process.They also explore the hidden risks of technology debt, why many manufacturers are sitting on “ticking time bombs,” and how failing to modernize foundational systems can lead to major operational disruptions.If you’ve ever struggled to justify digital investments or felt stuck between old systems and new technology, this episode gives you a clear, practical path forward.Key Takeaways:Proof of value matters more than proof of conceptYou can’t improve what you can’t see—data visibility is criticalStart small, but build a strong digital foundationIgnoring technology debt creates major future riskLinks:Lean Solutions 2026 SummitLean Solutions Websitehttps://realisepotential.com.au/https://www.linkedin.com/in/johnsbroadbent/

What You’ll Learn in This Episode:In this episode, Andy Olrich, Patrick Adams, and guest John Broadbent break down what Industry 4.0 really means, and why it’s not as complex or expensive as many think.You’ll learn how to start small, connect existing systems, and use data more effectively to improve operations. The conversation highlights why Industry 4.0 is about integration, not technology, and how even simple steps, like auditing spreadsheets or connecting one machine, can kickstart your transformation.If you’ve ever thought “we’re not ready for Industry 4.0,” this episode will challenge that belief and give you a practical starting point.Key Takeaways:1. Industry 4.0 isn’t about technology, it’s about integration2. Industry 4.0 is a journey, NOT a one-time project3. Visibility is the first step to transformation4. Context matters more than dataLinks:Lean Solutions 2026 SummitLean Solutions Websitehttps://realisepotential.com.au/Email: john@realisepotential.com.au

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald break down one of the biggest reasons Lean fails in organizations, and how it has nothing to do with the tools.Most companies try to “sell Lean” as a program or initiative, which immediately creates resistance. Employees see it as something being done to them instead of for them. But the real key to success is much simpler: stop selling Lean and start solving real problems that people face every day.The conversation dives into how leadership behaviors shape culture, why small wins matter more than big projects, and how building trust through employee involvement can transform an organization. You’ll also learn why traditional reward systems often backfire, and how to create a continuous improvement system that actually sticks.If your Lean efforts feel stuck—or your team isn’t buying in—this episode will completely change how you approach transformation.Key Takeaways:1. Stop selling Lean—start solving real problems2. Leadership behavior—not tools—determines success3. Small wins build trust faster than big initiatives4. Lean must be a system, not an eventLinks:Lean Solutions 2026 SummitLean Solutions Website

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Patrick Adams and Shayne Daughenbaugh sit down with Lean expert Darren Walsh to uncover why most Lean transformations stall, and what leaders must do to accelerate real business transformation.With more than 25 years of experience working with world-class organizations, Darren explains why many companies struggle with continuous improvement despite investing heavily in Lean tools like Kaizen and value stream mapping. The problem isn’t the tools; it’s the leadership mindset, flawed improvement strategies, and a focus on efficiency instead of value flow.The conversation explores how daily management systems, visual management, leadership routines, and better problem-solving can dramatically accelerate Lean results. Darren also shares practical strategies leaders can use to ensure teams work on the right problems, remove organizational blockers, and build sustainable continuous improvement habits.If your Lean initiative feels stuck, this episode reveals the leadership shifts needed to unlock faster transformation and lasting operational excellence.Key Takeaways:1. Most Lean transformations fail because leaders focus on efficiency instead of value flow2. Delegating improvement kills continuous improvement3. Daily management is the foundation of Lean success4. Most teams are solving the wrong problemsLinks:Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Darren Walsh's LinkedInhttps://www.makingleanwork.org/

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, hosts Patrick Adams and Shayne Daughenbaugh are joined by Marco Dannerhill to explore how Lean thinking must evolve in today’s fast-changing business environment. Drawing on more than three decades of experience in the plastics industry, Marco shares how Lean has shifted from focusing on localized process improvements to becoming a more strategic approach that supports long-term business success.The conversation dives into how global uncertainty, supply chain disruption, and emerging technologies like AI are changing the way organizations operate. Marco emphasizes that while technology can enhance productivity, people remain the heart of Lean, and leadership must prioritize coaching, mentoring, and building trust across teams. The discussion also highlights the importance of aligning improvement initiatives with strategic goals, empowering employees to lead smaller improvements, and ensuring that Lean efforts contribute to long-term growth rather than just short-term gains.Key Takeaways:Lean must evolve from local improvements to strategic impactTechnology should support people, not replace themLeaders must coach and mentor to build a culture of improvementStrategy must be translated so frontline teams understand their roleLinks: Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Marco Dannerhill's LinkedIn

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, hosts Patrick Adams, Andy Olrich, and guest Steve Riley discuss the importance of leadership behaviors in maintaining Lean initiatives. They highlight how unintentional actions, such as not picking up trash or not following standard work, can undermine Lean efforts. Steve Riley, a manufacturing operations leader with over 30 years of experience, emphasizes the need for consistent leadership presence, protecting standards under pressure, and fostering team-led improvements. They also explore the significance of measuring both leading and lagging indicators to ensure continuous improvement. Additionally, Riley introduces his company's digital shadow board service, which simplifies the creation of tool organization systems.Key Takeaways:Leadership behavior matters more than Lean toolsWhat leaders do in the moment defines credibilityLean breaks when standards are optionalImprovement must be part of daily workLinks:Lean Solutions 2026 SummitLean Solutions WebsiteClick Here for Steve Riley's LinkedInbespoketooltrays@gmail.comTool Box Foam, 5S Lean, 5 S Lean | BespokeToolTrays.com

What You’ll Learn in This Episode:In this second part episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh discuss the initial steps for a new leader implementing Lean principles. They emphasize understanding the current state through one-on-one interviews and Jeff Liker's leadership development model, which includes personal development, coaching others, daily Kaizen, and establishing a vision. Patrick advises starting with a model area to experiment with Lean concepts on a smaller scale. Shayne shares his experience of finding a champion and creating a safe space for experimentation. They both stress the importance of learning from failures, building team capability, and gradually introducing Lean practices to achieve organizational goals.Key Takeaways:Start Lean by Understanding the Current State—Not by Teaching ToolsYour First 90 Days Should Focus on Leadership Development, Not ControlCreate a “Sandbox” or Model Area to Learn Fast and SafelyFailure Is a Win When Learning Is the GoalLinks:Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠⁠

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Patrick Adams and Shane Daughenbaugh explore what the first 90 days should look like after discovering Lean or stepping into a new organization. Once someone understands the principles of continuous improvement, what should they actually do first? They discuss how your approach must shift depending on your level of influence. Whether you’re an executive, middle manager, or individual contributor, rushing into tools and events can create resistance instead of momentum.They advise spending time in direct reports' roles, having one-on-one conversations, and documenting feedback to identify common issues and improve processes. They also highlight the value of using emotions as flags and leveraging AI to analyze data for better decision-making. They agree on the importance of empathy and trust-building in leadership.Key TakeawaysYour Role Determines Your StrategyStart with Listening, Not ImplementingCulture Before ToolsPerspective Changes EverythingLinks: Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠⁠

What You’ll Learn in This Episode:In this episode of the Lean Solutions Podcast, Andy Olrich and Catherine McDonald explore what happens after the strategy day is over. Once goals are set, how do organizations move from planning to real execution? They highlight the challenges of managing too many goals and the necessity of engaging teams in the strategy process. They unpack why teams often struggle—not because they lack ideas—but because they have too many priorities and not enough clarity on where to start. The discussion focuses on practical frameworks for filtering, prioritizing, and executing goals in a way that aligns strategy with daily work.Key Takeaways:Teams don’t struggle from a lack of ideas—they struggle from too many priorities.Don’t start where it’s exciting—start where it’s expensive.Use structure to remove subjectivity.Links: Lean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Catherine McDonald’s LinkedIn⁠⁠⁠⁠Click Here For Andy Olrich’s LinkedIn⁠⁠

What You’ll Learn in This EpisodeIn this episode, hosts Catherine McDonald and Shayne Daughenbaugh discuss what coaching in the workplace really means. Why it’s far more than a buzzword. The conversation breaks down the difference between coaching, training, and mentoring, and explains how coaching serves as a powerful leadership approach for developing people, building trust, and sustaining continuous improvement.They emphasize how coaching shows up in day-to-day work through huddles, Gemba walks, and one-on-ones, and how lean tools like PDCA naturally support a coaching mindset. Key TakeawaysCoaching is a leadership approach, not an event.Coaching is different from training and mentoring.Every day work creates coaching opportunities.LinksLean Solutions 2026 SummitLean Solutions Website⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠Click Here For Catherine McDonald’s LinkedIn⁠⁠

What You’ll Learn: The second half dives deeper into the people side of continuous improvement. Dave explains how Nemawashi and intentional conversations help build alignment, trust, and momentum. Listeners learn why asking thoughtful questions—like “who else should we talk to?”—can naturally expand buy-in and lead to better decisions. The episode wraps with reflections on leadership, learning, and staying connected within the Lean community.Key Takeaways:How Nemawashi helps build buy-in naturallyWhy asking “who else should we talk to?” strengthens decisions and alignmentHuman, Pet, and Animal Nutrition Company: WebsiteClick Here for Dave Kippen's LinkedInLean Solutions Website

What You'll Learn: In the first half of the episode, the conversation focuses on the foundations of effective change and project success. Dave shares insights on the importance of executive support, strong project management, and understanding the real problems teams are trying to solve. The discussion highlights why improvement efforts often stall and how leaders can create clarity by engaging the right stakeholders early.Key Takeaways:Why executive support can make or break improvement effortsHow a clear problem definition sets the foundation for successLinks: Click Here for Dave Kippen's LinkedInHuman, Pet, and Animal Nutrition Company: WebsiteLean Solutions Website

The Lean Solutions Podcast hosts start off season 5 by addressing a common challenge: setting goals is easy, but making them stick is not. They emphasize that meaningful goal setting requires clarity, alignment, and intention, warning that vague goals and misaligned priorities often lead teams off track. From the start, they frame goals as something that must connect directly to daily work and organizational purpose.They go on to highlight the importance of systems like leader standard work and visual management to support consistent execution. The hosts stress accountability rooted in psychological safety, regular check-ins, and a focused set of three to five goals supported by leading indicators. The episode concludes with a call to action for listeners to put these ideas into practice and ensure their goals align with both their organization’s objectives and culture. 

What You’ll Learn:Join the Lean Solutions Podcast hosts as they discuss the importance of reflection and goal-setting for 2026. They shared personal reflections on habits, such as overcooking presentations and non-use of talent, and the significance of being grounded and customer-focused. The team also discussed the eight wastes of lean to identify and improve personal habits.Links:Lean Solutions 2026 SummitLean Solutions Website⁠Click Here For Catherine McDonald’s LinkedIn⁠⁠⁠⁠Click Here For Andy Olrich’s LinkedIn⁠⁠⁠⁠Click Here For Shayne Daughenbaugh’s LinkedIn⁠⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠⁠

What You’ll Learn:In this episode, host Patrick Adams interviews Natalie Howden, a new team member at Lean Solutions, about her career journey and the importance of standard work in Lean environments. Natalie shares her background in pharmaceuticals, lithium-ion, and office furniture, highlighting her transition from a scientist to a Lean Six Sigma Black Belt. She emphasizes the value of standard work in achieving consistency and improving processes, using examples from her experience.About the Guest:As an Executive Lean Coach at Lean Solutions, Natalie Howden helps organizations transform how they operate by reducing waste, accelerating flow, and embedding continuous improvement into everyday culture. Lean Solutions’ mission is to empower people through training, coaching, and talent solutions. Building the skills, systems, and culture needed for sustainable success.Partnering with organizations across manufacturing, healthcare, services, and professional industries, Natalie identifies inefficiencies and quality gaps and applies proven lean tools to redesign processes and deliver greater value with fewer resources. Through coaching leaders and teams, she builds lasting problem-solving capabilities and drives sustained performance by aligning systems, structures, and behaviors with lean thinking.Links:Natalie Howden's LinkedInLean Solutions 2026 SummitLean Solutions Website

What You’ll Learn:In this episode, host Catherine McDonald and guest Kelly Mallery discuss the importance of understanding and managing resistance to change in the workplace. They emphasize that resistance is a natural human reaction rooted in fear and that fighting it can be counterproductive, leading to eroded trust and failed change initiatives.About the Guest:Kelly Mallery has built her career helping teams and leaders navigate change—not by pushing harder, but by making the process easier, smarter, and even enjoyable. As the Operational Excellence Leader for two Viant Medical sites in New Hampshire and Michigan, she drives continuous improvement in high-stakes manufacturing environments. With over a decade of experience across solar, industrial consumer products, and aerospace, Kelly believes true transformation starts with mindset, not just tools.Through her coaching and consulting work, Kelly helps women change leaders overcome resistance, build confidence, and create lasting impact with less struggle. A proud Kata geek, she joined Kata Girl Geeks in 2020 and founded Kata School Northeast in 2023 to expand scientific thinking and adaptability. She lives in the Upper Valley between Vermont and New Hampshire with her family, where she continues her mission to make change work for people—not against them.Links:Kelly Mallery Coaching & Consulting LLCKelly Mallery's LinkedIn

What You’ll Learn:In this episode, hosts Andy Olrich, Catherine McDonald, and guest Wendy Sellers discuss positive leadership. They define positive leadership as focusing on strengths, optimism, and psychological safety, which fosters continuous improvement through ongoing learning and experimentation. They emphasize the importance of accountability, high standards, and clear company values. Wendy shares her experience with both positive and negative leadership, highlighting the need for realistic, respectful, and encouraging management.About the Guest:Wendy Sellers, The HR Lady®, is a nationally recognized HR Consultant, Speaker, Trainer, Podcaster, Author, and Mentor, as seen in USA Today and the International Business Times. Known for her direct, no-nonsense approach delivered with respect, Wendy empowers organizations to treat people as their greatest asset. She equips leaders, managers, and administrators with the skills and confidence needed to navigate HR compliance, workplace culture, and the full employee lifecycle—from hiring to termination.With 30 years of experience across for-profit, non-profit, government, and defense organizations, Wendy brings a rare blend of practical insight and strategic vision. Her career began unexpectedly in an Orlando engineering firm and grew alongside the company’s national and global expansion. Backed by multiple degrees and HR certifications, Wendy is driven by a clear mission: to help leaders build successful companies that employees don’t feel the need to escape.Links:The HR Lady LLCWendy Sellers's LinkedIn

What You’ll Learn:In this episode, hosts Andy Olrich, Shayne Daughenbaug, and guest Alex Suchman discuss how play can serve as a powerful tool for continuous improvement and stronger team performance. They highlight how workplace disagreement often stems from interpersonal dynamics and different communication styles. They also emphasize that play can foster trust, accountability, and psychological safety.About the Guest:Alex Suchman is the CEO and co-founder of Barometer XP, whose mission is to create cultures where people are excited about their work because they feel a strong sense of purpose and belonging. She uses games and play to strengthen interpersonal dynamics, such as trust, accountability, and psychological safety, in the workplace. She was a finalist for the Metro DC ATD Award for Excellence in Innovative Learning, has been featured in Forbes, and is a sought-after speaker and thought leader on using play as a tool for organizational effectiveness and employee success.Links:Alex Suchman LinkedInBarometer XP Website

What You’ll Learn:In this episode, hosts Patrick Adams and Andy Olrich discuss the importance of soft skills in leadership, emphasizing empathy, communication, adaptability, and emotional intelligence.About the Guest:Andy Olrich brings over 25 years of expertise in engineering trades, services, manufacturing, mining and logistics processes and support. With qualifications in Continuous Improvement and LEAN Six Sigma, he is also a Certified Scrum Master. Andy finds fulfillment in witnessing the positive outcomes that result from teams collaboratively working towards shared and individual goals.Patrick Adams is an internationally recognized leadership coach, consultant and professional speaker. He is best known for his unique human approach to sound team building practices, creating consensus and enabling empowerment.Patrick has been delivering bottom-line results through specialized process improvement solutions for over 20 years. He’s worked with all types of businesses from private, non-profit, government, and manufacturing ranging from small business to billion-dollar corporations. Patrick is an Author of the best selling book, Avoiding the Continuous Appearance Trap.Links:⁠Click Here For Andy Olrich’s LinkedIn⁠⁠⁠Click Here For Patrick Adams’ LinkedIn⁠

What You’ll Learn:In this episode, hosts Catherine McDonald, Andy Olrich, and guest Leire Martinez discuss the importance of sustaining culture and connection in organizations. They emphasize that culture is crucial for continuous improvement and can vary across different departments and regions.About the Guest:With a strong Lean Six Sigma background, she is experienced as an Operations Director managing multi-site operations, as well as a Plant Manager, Production Manager, and Continuous Improvement Manager in the automotive sector within a VUCA environment and during challenging periods such as COVID, the chip crisis, and material shortages. Her aim is to inspire the teams she works with to achieve results as one, always acting with integrity, a willingness to win, and a commitment to making tomorrow better.Links:Click Here For Leire Martinez LinkedIn