Is It Time to Improve Continuous Improvement Methods?

Each of my Continuous Improvement (CI) experts has their go-to CI process—whether it’s Lean, TPS, Six Sigma, or the Theory of Constraints (TOC). These methods have been tried and tested, each delivering results in the short term. However, they share a glaring weakness—they all tend to fail in the long term.

CI experts often find themselves frustrated, confused and bewildered as the initial improvements achieved by these methods start to taper off. They wonder why the success doesn’t last, and they’re left searching for answers. If this kind of short-lived success rate happened within a manufacturing process, it would be a major focus of improvement efforts. Yet, like many organizations, we often resist change. So why should we be any different?

I propose that it’s time to examine these CI methods through a different lens, one I call Holistic Thinking. This approach is rooted in long-term success and sustainability, unlike the traditional methods that fizzle out after the initial excitement. One key example of Holistic Thinking in action is the Throughput Improvement Process (TIP), which has generated billions of dollars in increased profits, improved On-Time Performance to the mid-90s, reduced inventory levels, and revolutionized scheduling methods across organizations.

What makes TIP so different is its long-term sustainability. It doesn’t just work well at the start—it keeps working, often becoming viral as it’s adopted by other parts of the organization. Even more impressive, TIP requires minimal effort to maintain. Initially, it relied on management mandates, but as team members began to succeed and take ownership of the process, the need for top-down pressure faded. This kind of sustained ownership is what makes TIP stand out from other CI methods that often struggle to survive management churn.

To understand why it works so well, we have to look deeper—into how the brain makes decisions and creates habits. The brain’s reward system, powered by chemicals like dopamine, plays a key role in reinforcing behaviors. When a method like TIP creates rewarding results, it forms new habits that drive ongoing success, even in the absence of constant management oversight. However, fear-based brain chemicals (such as cortisol) can also drive resistance to change. That’s why CI processes often fail when they rely solely on mandates and don’t address the deeper, habit-forming mechanisms that sustain change.

Holistic thinking demonstrates how leveraging brain chemistry, habits, and behavior can lead to long-term success in CI processes. It’s a case study of how to improve the very methods we use for improvement.

I’ve been tackling these issues for years, and I have developed methods that can significantly enhance the long-term effectiveness of any CI process. If you’re a CI expert who’s tired of seeing your improvements fizzle out in three to five years, or you’re unhappy with the status quo, I’d love to help you take your CI process to the next level.

Are you interested in becoming the subject matter expert on how to improve your passion? Is the future value of your efforts worth a half-hour conversation?

Let’s talk about how Holistic Thinking can make your CI process succeed in the long run—because improving your improvement methods is the next step toward sustained success.

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