My guest for Episode #514 of the Lean Blog Interviews Podcast is Hugh Alley, an author and consultant. He divides his time between coaching senior operational leaders in continuous improvement, training front-line leaders in core supervisory skills, and designing industrial facilities. 

An industrial engineer, he has run three manufacturing and distribution firms, and a department in a government agency, teaching skills to over 1,000 front-line leaders. 

He has written two books: Becoming the Supervisor: Achieving Your Company's Mission and Building Your Team, and The TWI Memory Jogger.

He frequently speaks about supervision, quality, lean manufacturing, and Toyota Kata. From his home near Vancouver, Canada, he helps clients across North America.

In today's episode, we explore the power of TWI (Training Within Industry), its impact on building trust and improving workplace culture, and stories of real-world applications in manufacturing and sports. From reducing cycle times to fostering better leadership, this episode covers key lessons in Lean methodology. Tune in to hear about Hugh's Lean origin story and his experiences in applying Lean principles across various industries. Don't miss out on a thoughtful discussion that blends Lean, leadership, and even hockey!

Questions, Notes, and Highlights:

• What kind of government agency did you work for?



• How did you reduce lead times for occupational disease claims?



• What is your lean origin story? Where, when, and why were you introduced to lean?



• Was the word "Kaizen" used in your early lean experiences?



• Is job relations typically the starting point in TWI, or does it depend on the culture?



• What parallels do you see between sports coaching and leadership in the workplace?



• How can you tell if a workplace problem is due to tactics, teamwork, or culture?



• What role does continuous improvement play in sports teams' success, and can it happen game to game?



• How do you see the role of fear in leadership and coaching, and what impact does removing a "bully" leader have on a team?



• How can job instruction and job relations contribute to better workplace culture and performance?



• How do you approach the challenge of hiring the right people and fitting them into a lean system?



• How did TWI help one of your clients shorten training times and reduce bad product?



• What opportunities do you see for companies to create "practice days" similar to sports teams?



• How do you convince leaders to care about improving their supervisors' skills?



• What role does a coach or leader play in creating the right context for their team to succeed?



• What do you think makes a great player transition into a great coach?



• How do you use the TWI model to break down jobs and help people learn faster?



• What's your take on benchmarking against others in the industry?



• How did you help reduce patient waiting times in a medical lab by aligning priorities?



• Was Wayne Gretzky's coaching career unsuccessful, or did he just pick the wrong job?



• How do you translate great skills into effective coaching, and how does TWI help with that?

The podcast is brought to you by Stiles Associates, the premier executive search firm specializing in the placement of Lean Transformation executives. With a track record of success spanning over 30 years, it's been the trusted partner for the manufacturing, private equity, and healthcare sectors. Learn more.

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