Behind the Curtain: Adventures in Continuous Improvement

Behind the Curtain: Adventures in Continuous Improvement

Longtime manufacturing process engineer and trainer John Dyer discusses operational excellence and continuous improvement with Professor Mohamed Saleh, a Lean, Six Sigma and continuous improvement expert. Between them, the two share nearly 60 years of continuous improvement expertise. IndustryWeek has partnered with Dyer and Saleh to present their insights to a wide audience of manufacturing professionals.

Episodes

September 30, 2025 22 mins

Respect for people isn’t a slogan—it’s a leadership condition. Tune in to discover why it’s time to flip the script and treat respect for people as the root of transformation.

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Learn how engaging with your team at the gemba, or where the work happens—and with the right mindset—builds trust, amplifies decision-making and creates psychological safety.

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Explore how true leaders adopt a team-over-self mindset, embody humility and prioritize removing obstacles for their teams.

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September 23, 2025 19 mins

Explore how to create a training roadmap that drives genuine lean leadership and avoids the pitfalls of empty certification. Learn the dangers of taking a cookie-cutter approach. 

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September 22, 2025 24 mins

Explore how to craft training experiences that don’t just deliver knowledge but ensure it is gained, transferred, and retained. Review dynamic approaches like simulations, on-the-job training, breakouts, and role-playing.

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Explore the difference between training that sparks meaningful improvement and training that falls flat. Learn about the most effective approaches—like hands-on simulations and engaging adult learners through active participation—versus the common pitfalls of overloading with theory or skipping leadership involvement.

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Dive into what happens when the push for progress becomes a burden rather than a boost. How do you keep your people engaged and inspired when they’ve been burned before, or when they’re simply recovering from the last big change?

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Dive into one of the most challenging dynamics of organizational change and leadership change resistance: navigating the loss of control during times of change. As leaders shift from the familiar role of the “firefighter hero” to empowering their teams as the true heroes, they face a profound identity shift. How do we retire that hero’s cap and elevate others through recognition and a reward system that celebrates the best coaches,...

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Explore the psychological and emotional drivers behind this resistance, and learn how leaders can recognize these barriers and implement strategies to transform resistance into acceptance, turning potential roadblocks into opportunities for innovation and improvement.

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Traditional vertical hierarchies often stifle communication, slow decision-making and create barriers to innovation. Shifting to a horizontal, decentralized structure can break down these barriers and foster a culture of open, two-way communication. Explore strategies for leaders looking to implement horizontal communication channels in their organizations.

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Dive deep into the destructive impact of organizational silos. Explore how these invisible walls form and learn strategies to break them down, paving the way for seamless teamwork and continuous improvement. 

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Discover how open communication is not just a tool but a mirror reflecting the ongoing culture within your organization. We’ll discuss real-world examples, like hour-by-hour metric boards. Are they tools for improvement or instruments of blame?

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Uncover the blueprint for fostering two-way communication that ignites collaboration and innovation. From tiered huddles to activating listening structures and rituals that prioritize dialogue over directives, explore how flattening organizational structures can break down barriers and foster a culture of openness and trust.

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Explore the true power of employee engagement. Discover how sincere, empathetic, and respectful engagement can transform the narrative from “I” to “We,” fostering ownership, buy-in, and enthusiastic productivity.

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Discover the skill of active listening and how to identify and engage with the tribes within your organization. Learn how to create triads to break down competitive silos, establish shared values, and unite everyone in pursuit of a noble cause.

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Dive into three pivotal moments from "The Facade of Excellence: Defining a New Normal of Leadership," written by  podcast co-host John Dyer.  The book isn’t just a narrative; it reflects real-life struggles and triumphs. Told through the eyes of fictional executives Jim Brown and Frank Smith, you’ll explore the clash of new and old management styles.

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Delve into the challenge of maintaining core values in the workplace while addressing toxicity head-on. Identifying values and behaviors that promote collaboration, teamwork, and improvement is essential, but living by these values daily is the real test. This episode explores these complex dynamics, including how to handle the “firefighter” employee who thrives on chaos and may sabotage improvements to maintain their hero status.

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Explore actionable strategies for leaders to build trust, foster psychological safety, and create a culture where employees feel secure to share ideas, take risks, and contribute to continuous improvement. Additionally, uncover the damaging actions that can quickly destroy an environment of trust and collaboration.

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Dive deep into the rituals that redefine leadership: appreciation walks, waste walks, standard work observations, kaizen participation, delivering impactful training, and conducting 5S audits. Discover why lean is not a spectator sport and how true leaders lead by example.

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Dive deep into the four distinct leadership styles, ranging from dictator to collaboration, and explore how recognizing and adapting these styles can drive organizations toward genuine empowerment and teamwork.

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