Lean Archives | Gemba Academy

The Trouble With Averages

By John Knotts - May 22nd, 2026

One of the biggest mistakes in process improvement is believing that the average tells the whole story. For years, process improvement has relied heavily on averages. Average cycle time. Average defect rate. Average wait time. Average

GA 633 | Be Curious and Seek Knowledge with Andy Olrich

By Jessica Bush - May 21st, 2026

This week’s guest is Andy Olrich. Ron and Andy discussed the roles of people and tools in continuous improvement, what NOT to do when building a lean culture, teaching younger generations, and more. An MP3 audio version of this e

Ego: The Quiet Enemy of Leadership

By Ron Pereira - May 20th, 2026

A few days ago, I found myself getting pretty frustrated with someone in my life. This person was asking me to do something I really didn’t want to do, and I had already made a solid case for why I was right and they were wrong. Look

GA 632 | Performance Unleashed with Chris Libutti

By Jessica Bush - May 14th, 2026

This week’s guest is Chris Libutti. Ron and Chris discussed Chris and his wife Yamila’s book, “Performance Unleashed,” his time in the military, the importance of self-discipline, and more. An MP3 audio version

Choosing Joy on the Side of I-635

By Ron Pereira - May 13th, 2026

Monday evening was one of those days that felt like a lifetime packed into a few short hours. It started in Steubenville, Ohio, at Franciscan University, where my daughter Brenna graduated from college this past weekend. As a father, t

Start Every Process Improvement Effort with the Primary Metric

By John Knotts - May 8th, 2026

One of the most common mistakes in process improvement projects is also one of the most avoidable. Teams start with ideas. They start with complaints. They start with what they believe is wrong. What they don’t start with is data. An

GA 631 | What We Can Learn from Tetris with Michael Parent

By Jessica Bush - May 7th, 2026

This week’s guest is Michael Parent. Ron and Michael discussed an interesting AI conundrum, the impact that systems and design have on performance, Michael’s Tetris experiment, and more. An MP3 audio version of this episode

Elite marathon runners competing in a race, illustrating high performance and endurance

Stop Looking for Faster Runners

By Ron Pereira - May 6th, 2026

A little over a week ago, something happened in the world of marathon running that many thought to be impossible. Two runners broke the two-hour marathon barrier. Not one…two! Kenya’s Sabastian Sawe finished in 1:59:30, just 11 sec

GA 630 | Why Tone Matters with Shahab Shah

By Jessica Bush - April 30th, 2026

This week’s guest is Shahab Shah. Ron and Shahab discussed the importance of balancing human empathy with the demands of reality, why tone matters, first steps for making improvements, and more. An MP3 audio version of this episo

The Angel in the Marble

By Ron Pereira - April 29th, 2026

I recently came across a quote normally attributed to Michelangelo that I can’t stop thinking about. “I saw the angel in the marble and carved until I set him free.” Notice he didn’t say he built the angel. Instead,

A New Way to Look at 5S

By John Knotts - April 24th, 2026

Most people think they understand 5S. They associate it with cleaning, organizing, and maybe putting tape on the floor. In many organizations, that is exactly what it becomes. A one-time cleanup event followed by a slow return to the w

GA 629 | Why Leadership Is Like Cooking with Pete Behrens

By Jessica Bush - April 23rd, 2026

This week’s guest is Pete Behrens. Ron and Pete discussed Pete’s book, “Into the Fog,” what it means for leaders to face uncertainty, why leadership is like cooking, and more. An MP3 audio version of this episod

Whispering Names, Remembering Blessings

By Ron Pereira - April 22nd, 2026

Disclaimer: This blog article is more personal in nature. On Monday mornings at 6:00 am I spend an hour in the adoration chapel at my church. It’s a time for quiet contemplation and prayer. Normally, I find myself asking for th

Are Your Five Whys Turning into a Tangled Mess?

By John Knotts - April 17th, 2026

If your Five Whys sessions feel like they’re going in circles, you’re not alone. What starts as a simple exercise often turns into a tangled mess of guesses, side paths, and competing opinions. The problem isn’t the tool itself,

GA 628 | A Factory on Fire: How Lean Saves Lives with Brian Meyers

By Jessica Bush - April 16th, 2026

This week’s guest is Brian Meyers. Ron and Brian discussed the heart-stopping story of how Brian’s facility caught fire, the profound difference lean made in saving it, what “unwavering commitment” means, and mo

Getting to 80%

By Ron Pereira - April 15th, 2026

I recently worked my way through a fantastic podcast between Arthur Brooks, a professor at the Harvard Business School, and Tim Ferriss. Brooks studies the idea of happiness and has written many books on the subject. While there were a

GA 627 | Value Stream Mapping on University Campuses with Kristin Kielich

By Jessica Bush - April 9th, 2026

This week’s guest is Kristin Kielich. Ron and Kristin discussed Kristin’s experiences with continuous improvement in education, dealing with resistance, measuring success, and more. An MP3 audio version of this episode is a

Why Proper Root Cause Analysis Matters

By John Knotts - April 8th, 2026

The post below was written by Gemba Academy Master Black Belt Candidate Noah Waech. Noah was also recently on our podcast. Thank you for sharing your knowledge with us, Noah! Root cause analysis can be one of the simplest and mo

Occam’s Razor and Lean Thinking

By Ron Pereira - April 8th, 2026

Occam’s Razor is a principle that dates back to the 14th century and is attributed to the English Franciscan friar and philosopher William of Ockham. It simply says: When multiple explanations exist, start with the simplest one. Not

GA 626 | Learning to See Waste with Randall Dupre

By Jessica Bush - April 2nd, 2026

This week’s guest is Randall Dupre. Ron and Randall discussed Randall’s book, “Everyday Lean,” the kinds of mistakes Randall sees people making, what good leadership looks like, his favorite lean principles, and

Why Project Management Skills Are Essential for Everyone

By John Knotts - April 1st, 2026

When people think about process improvement, they often think about approaches and tools. Things like Value Stream Mapping, Root Cause Analysis, Control Charts, DMAIC, Fishbone Diagram, etc. But here’s the truth: Process improvement

Is the Universe Working Against You, or For You?

By Ron Pereira - April 1st, 2026

I want you to imagine it’s Monday morning and you’re on your way to work. Everything’s going as well as can be expected in rush hour until, out of nowhere, some guy cuts right in front of you, causing you to slam on y

GA 625 | Dealing with Hidden Threats with Dean Svarc

By Jessica Bush - March 26th, 2026

This week’s guest is Dean Svarc. Ron and Dean discussed Dean’s book, “Trojan Horse,” navigating hidden threats, why culture matters, the mistakes leaders make, and more. An MP3 audio version of this episode is a

Do Buffalo Really Run Toward Storms?

By Ron Pereira - March 25th, 2026

You may have heard the story before. When a storm rolls across the plains, buffalo don’t run away from it…they run into it. The idea is that by facing the storm head-on, they get through it faster than if they tried to outrun it. I

GA 624 | The Pause, Consider, Act Framework with Ashley Herd

By Jessica Bush - March 19th, 2026

This week’s guest is Ashley Herd. Ron and Ashley discussed Ashley’s Pause, Consider, Act Framework, the concept of a career quilt, micromanagement, and more. An MP3 audio version of this episode is available for download he

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