2nd Lean Journeys: Global Stories Recap-Expert Perspectives on Continuous Improvement

A Kaizen Institute North America Newsletter

The latest edition of the Lean Journeys: Global Stories webinar, moderated by Patricia Paiva , Senior Manager at Kaizen Institute, brought together industry leaders to share insights and experiences on Lean methodologies and Continuous Improvement in the Chemical Manufacturing, Automotive, and Food & Beverages industries.?

The speakers, Paul Winkley (Plant Manager at Mallard Creek Polymers Polymers), Thomas Morris (Divisional Group Kaizen Manager at Multimatic ), and Larry Johnson (former Head of Operational Excellence at ofi ), shared insights on overcoming challenges, success stories, and trends like digital transformation and sustainability.?

The webinar highlighted the importance of adaptability and continuous improvement implementation for long-term business success, offering valuable lessons and practical ideas for Lean implementation.?

Challenges and Opportunities??

Implementing Lean practices often comes with challenges like cultural resistance and leadership alignment, but these also offer opportunities for transformation and innovation.?

One of the most common barriers in Lean implementation is resistance to change. Paul Winkley illustrated this with a common concern frequently voiced by his team: “One of the challenges that I’m facing with my team is this sense that this culture, this program, is going to add nothing but bureaucracy - another report to fill out, another board to write on.”? To change this perception, it’s essential to show how Lean simplifies processes rather than complicates them, using real examples of benefits to encourage acceptance.?

Thomas Morris emphasized that adaptability is key to Lean adoption since a one-size-fits-all approach rarely works. Patience, flexibility, and communication are crucial for overcoming resistance. Paul Winkley further explained that they are beginning to realize everyone learns differently, and not everyone in the business necessarily needs the same techniques or methodologies. This highlights the importance of recognizing that different individuals and business areas require different approaches rather than applying a uniform set of techniques or methodologies.?

Larry also addresses that leaders must model the behaviours they expect. However, when a crisis hits, old habits take over, and leaders often fall back into a directive approach, instead of fostering the intended culture.?

By addressing resistance, aligning leadership with strategic goals, and balancing cultural and operational needs, organizations can turn challenges into opportunities for lasting success. Emphasizing adaptability and clear communication ensures that Lean is seen not as a bureaucratic burden but as a practical tool for continuous improvement.?

Lean Success Stories?

Implementing Lean methodologies across industries has consistently proven to deliver remarkable results, improving efficiency and driving transformation in individuals and teams.?

Thomas Morris shared how Multimatic’s Kaizen efforts, through targeted coaching and the introduction of specific, simple tools into the routine, transformed a shy, reserved team member into a confident leader. By focusing on tools and methods tailored to the individual’s needs, the team empowered the individual to manage and overcome daily challenges more effectively. This approach showed how coaching and custom solutions support personal growth and leadership development.?

Larry Johnson shared how he transformed an underperforming bakery into the top operation in the organization by applying Lean principles like value stream mapping and collaboration. These efforts increased productivity and improved employee satisfaction. Reflecting on the transformation, he said, “We went from being last in the organization to first. The change was so dramatic that they thought we were cheating and sent an accounting team to audit us.” In addition to delivering measurable results, Lean principles encouraged a culture of continuous improvement. As Larry emphasizes, Lean proves that by implementing smarter, more efficient processes, work can become easier while still achieving superior outcomes.?

Ultimately, Lean is a mindset that drives transformation, empowers leaders, and improves operations.?

Employee Engagement?

The successful implementation of Lean practices depends on strong employee engagement, as continuous improvement can only thrive when everyone is involved, supported, and empowered. At the 2nd Edition of Lean Journeys: Global Stories, speakers shared how fostering engagement is key to driving meaningful and sustainable change.?

According to Larry, one critical element of engagement is establishing a solid Management Operating System (MOS). A strong MOS ensures that information flows both up and down the organizational system, creating transparency, accountability, and alignment.?

Employees need to feel that their voices matter and that their input drives significant change. As Larry emphasizes, when employees feel heard and see their suggestions recognized, it builds trust and motivates them to keep improving. Larry also highlights the importance of willingness and commitment to providing feedback, whether positive, constructive, or action oriented.? "When we come back in, everybody has an idea of how it can be done better, how it can be done easier”, he says.?

Leadership must actively acknowledge and act on employee suggestions. Engagement thrives when leaders are visible, approachable, and invested in their team. This two-way feedback strengthens processes and builds trust between employees and leadership. As Larry suggests, "Having your idea boards, having your pieces there, but having open discussion fosters collaboration and sparks innovation.?

Additionally, Paul Winkley emphasizes the importance of recognizing progress and celebrating achievements to sustain motivation, especially during challenging periods. He shares, “I purposely point out to my team or anybody that'll listen, let's look back a year ago or two years ago and remember how difficult it was and the struggle it was to meet this number and look where we are today.”?

These examples highlight a key message:? Lean is about building a culture of collaboration, recognition, and continuous improvement. Employee engagement isn’t a one-time initiative but a commitment to honesty, open communication, and feedback. When employees feel heard and valued, their ideas can drive real progress.?

Continuous Improvement Culture?

“Building the sustainability of a continuous improvement culture is fundamental for long-term success."?- Patrícia Paiva, Senior Manager at Kaizen Institute?

To sustain Lean success, continuous improvement must be embedded in daily routines and the organizational culture. Thomas emphasized the importance of consistency, stating, “It's that constant message to a standard, whether it's a daily meeting that we have, whether it's a weekly touch point, whether it's a monthly report that we're creating, we're all still using that same terminology.” He added, "Every level of communication from top to bottom is always following the same route".?

Paul explains that his team consistently tracked and prioritized key performance indicators (KPIs) throughout the process, measuring and keeping them front and center. Larry adds that this consistent attention to KPIs helps to create a culture of continuous improvement. When a KPI isn’t met, it sparks discussions about what’s missing, what actions to take, and how the team can work together to solve the problem. This process drives problem-solving and reinforces continuous improvement.?

A strong Lean culture is reinforced when leadership actively engages with employees:?

“(…) when the CEO goes on the floor (…), and they're asking questions using the same terms, recognizing the improvement that's been made, it really shows everybody that it's important to everyone and the entire team.”?- Paul Winkley, Mallard Creek Polymers?

This strategy brings Lean culture to the shop floor, demonstrating that it is a shared priority across all levels of the organization. When leaders stay visible, ask questions, and use consistent language, they reinforce that continuous improvement matters to everyone, from executives to frontline employees.?

Future Trends and Digital Transformation??

The rapid advancement of technology creates new opportunities for optimization through automation and analytics. These technologies improve efficiency, drive progress, and bring even greater potential for improvement.?

However, as Thomas Morris stresses, technology cannot replace understanding why a process needs improvement, and simplicity remains key to meaningful change.? While advanced technologies may seem appealing, they are not always the best solution. Meaningful improvements often come from making small, strategic changes:?

“You can come up with alternative solutions or alternative processes that can still give you the same results without that big heavy cost coming through. So simple is the best, understanding the process, understanding the product, the customer, the requirements. It doesn't always need that automation or advanced technology (...)”?-Thomas Morris, Multimatic?

Building on this, Larry emphasizes the importance of mastering the basics, stating, “Understanding the fundamentals of what your line needs to do, what your outputs are, what your capabilities are, and the capacity of your equipment and your people, I think it’s going to be even more important”. In short, Larry points out that knowing your operations inside and out is often more effective than relying on complex technology. By focusing on existing resources and processes, organizations can improve efficiency and achieve lasting results.?

Without proper understanding, advanced technology can add unnecessary complexity. Johnson stresses the importance of evaluating the entire process to ensure that technology supports the organisation’s goals and objectives:?

“I've seen a lot of times we've gone in and put this high technology in that's going to go super-fast. And guess what? The rest of the line can't keep up. Technology is going to keep advancing. (…) But all components of the operation must be taken into consideration when you're upgrading technology.”?- Larry Johnson, former Head of Operational Excellence for North America at Ofi?

Technologies like AI, machine learning, and virtual reality have great potential to streamline operations and improve decision-making. However, they should support Lean practices, not replace them. Organizations must balance innovation with Lean principles to ensure technology and Lean work effectively together.?

Sustainability and Lean?

Sustainability is a core aspect of Lean, combining waste reduction with environmental and operational efficiency. By integrating sustainability into Lean initiatives, organizations can enhance their ecological responsibility while boosting business performance, creating a competitive edge.?

Paul highlights the growing importance of sustainability, stating, “it is getting more important to our customers as well as our suppliers.” He explains that organizations are often asked to complete surveys from suppliers or customers, focusing on sustainability practices and performance while assessing a company’s environmental and operational responsibility.?

Customer expectations are shifting, with an increasing focus on sustainability and a demand for greater accountability in environmental and operational practices. To remain competitive, businesses must adapt to these evolving standards. Thomas Morris reinforces this point, stating, “If we are very aware of some of our activities having that sustainability impact, we can promote it to our customers. So, it gives us that edge over our competitors.” Paul adds, “And I think very soon customers may be asking in that same vein, do you have a continuous improvement program?”, suggesting that customers will value a company’s commitment to ongoing improvement in processes, products, and services.?

Thomas Morris of Multimatic stressed the importance of integrating sustainability into everyday operations, stating that “(...) every level of activity that we do within our Kaizen events has some level of sustainability impact.”? He also highlighted the link between cost efficiency and sustainability, explaining that by reducing production costs while maintaining a competitive selling price, the company can align with its sustainability goals.??

Ultimately, integrating sustainability with Lean principles creates a win-win scenario: it improves operational efficiency while addressing growing environmental concerns.?

Remote Work and Lean

Remote work has challenged traditional Lean practices, especially in industries like manufacturing that rely mainly on physical presence. However, organizations are finding ways to adapt Lean principles to this new setup.?

Thomas Morris underscores the value of hands-on learning and being physically present in the workplace to fully understand and absorb information.? However, it also acknowledges that remote work is sometimes necessary due to certain situations or constraints. The key takeaway is that “Lean principles don’t always have to be textbook (…)”, he says. He emphasizes that with the right tools and flexibility, technology can seamlessly connect remote workers and on-site teams, successfully aligning remote work with Lean practices.?

Adapting Lean practices to remote work means identifying which roles are suited for remote work and how they can support operations, “because all roles aren’t conducive to properly supporting the process.”, says Larry Johnson. He also highlights that hands-on training is best done in person, where you can “sense the room” and engage directly with the team.? By leveraging technology, clearly defining roles, and balancing remote and in-person work, companies can maintain and adapt Lean principles across various scenarios, ensuring both flexibility and effectiveness.?

The 2nd Lean Journeys provided valuable insights into how organizations can succeed by fostering strong leadership, engaging employees, and leveraging technology strategically.? By embracing Lean principles drive, companies can drive continuous improvement and sustainable growth and remain adaptable to thrive in an ever-evolving world.?

Watch the full Lean Journeys: https://kaizen.com/insights/second-edition-lean-journeys-global-stories-en/?