

Lean Six Sigma Bursts
Brion Hurley
Brion Hurley from Business Performance Improvement shares his takes and thoughts on a variety of topics related to process improvement (specifically Lean and Six Sigma methods), Bursts are rapid improvement activities, so this sounded like a good word to use for these short audio clips. We'll try to keep them under 10 minutes each. Have a question? Use the Spotify app to leave us a voice message, and we might pick your question for our next episode!
Episodes
Mentioned books

Jan 16, 2025 • 9min
E116: How a battery manufacturer saved nearly $1 million by completing only 7 Lean Six Sigma projects
In this podcast, I share a successful case study of a Lean Six Sigma training and certification program conducted for a battery manufacturer about 2 years ago. By completing real-life projects, they were able to payback the investment in the training in under one month!
Links
Manufacturer invests in Green Belt training that leads to significant savings and payback: https://www.biz-pi.com/manufacturer-invests-in-green-belt-training-that-leads-to-significant-savings-and-payback/
Learn more about BPI
7 Continuous Improvement Best Practices: https://mail.biz-pi.com/lss-best-practices-funnel
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Dec 12, 2024 • 5min
E115: How I use AI for my Lean Six Sigma Consulting
In this episode, I share a short segment of a recorded presentation I gave to the Continuous Process Improvement Forum hosted within the National Industries of the Blind. They wanted to hear my perspective on AI, so I shared how I've utilized for my consulting work.
NIB is a great organization whose mission is to enhance the opportunities for economic and personal independence of people who are blind, primarily through creating, sustaining, and improving employment.
Links
National Industries for the Blind: https://nib.org/
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Nov 25, 2024 • 10min
E114: Tackling Green with Lean - Energy Treasure Hunts
In the 2024 Lean Global Connection virtual conference, our Lean Sustainability community shared some tips and methods to help apply Lean to Green initiatives.
In my segment, I explained how Energy Treasure Hunts are a combination of gemba walks and kaizen events, with the goal to identify and reduce energy usage in a facility. This is a great approach that combines my passion for process improvement and sustainability.
The full presentation will be available in a few weeks (end of 2024), and I will post it in the Lean Six Sigma for Good podcast as soon as possible.
Links
Lean Global Connection: https://www.planet-lean.com/lean-global-connection-2024
Video from this presentation segment: https://youtu.be/OD0aZK8JptM
Energy Treasure Hunts Webinar: https://leansixsigmaenvironment.org/index.php/e116-using-energy-treasure-hunts-and-energy-swaps-to-engage-employees-and-reduce-costs/
About the Lean Sustainability Community: https://leansixsigmaenvironment.org/index.php/lean-sustainability-global-network/
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Nov 1, 2024 • 10min
E113: Explaining Energy Treasure Hunts with AI
Energy Treasure Hunts can be described as a combination of gemba walks and kaizen events in Lean methodology, with the goal to identify and reduce energy usage in a facility. This is a great approach that combines my passion for process improvement and sustainability.
I uploaded a recent webinar I did on Energy Treasure Hunts to AI (NotebookLM), and it generated a fake podcast episode between two robots, which was mind-blowing to hear.
I share segments from the "podcast" so you can hear how it sounds. Let me know what you think!
In summary, here is how NotebookLM summarized the webinar, which was well-stated:
"Energy treasure hunts and programs like the Better Buildings Challenge offer a powerful approach to identifying and implementing energy-saving opportunities. By engaging employees, leveraging data analysis, and fostering collaboration, organizations can achieve significant energy reductions, cost savings, and environmental benefits."
Links
NotebookLM from Google: https://notebooklm.google.com/
Energy Treasure Hunts Webinar: https://leansixsigmaenvironment.org/index.php/e116-using-energy-treasure-hunts-and-energy-swaps-to-engage-employees-and-reduce-costs/
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Oct 23, 2024 • 12min
E112: Lean Six Sigma for Good
In the last 2 episodes, I shared best practices in process improvement with students in the Florida Atlantic University (FAU) Executive MBA Program in Boca Raton, Florida.
At the end of my talk, I discussed how Lean and Six Sigma can be used to improve society and the environment, which I call Lean Six Sigma for Good. I share some examples and discuss my own experiences, hand out copies of Volume 1 and 2 of the book series, and encourage the students to help me connect with some local nonprofits.
Additional Links
Full presentation with slides (YouTube)
Lean Six Sigma for Good book series
Florida Atlantic University Executive MBA Program
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Oct 14, 2024 • 10min
E111: Lean Six Sigma Best Practices - Part 2
Discover the power of daily huddles for fast problem-solving and performance reviews. Learn how to prioritize improvements using Pareto charts, addressing the biggest issues first. Explore how Toyota fosters a culture of problem detection and coaching rather than merely copying solutions. Brion emphasizes the importance of statistical thinking to differentiate between consistent process issues and random variations. Finally, find out how to protect time for kaizen and risk prevention to create a proactive improvement culture.

Oct 9, 2024 • 8min
E110: Lean Six Sigma Best Practices - Part 1
This is a list of best practices in process improvement I shared with students in the Florida Atlantic University (FAU) Executive MBA Program in Boca Raton, Florida last month. I compiled my top recommendations that they could take back to their company.
Focused on building problem solving and
waste identification skill set of lowest-level employee
Psychological safety to discuss and solve problems
Management horizontally across value
stream
Making decisions that are best for the system, not individual departments (vertical)
Aligned and balanced metrics (two-way
communication or “catchball”)
Not just lagging financial metrics
Additional Links
Full presentation with slides (YouTube)
Lean Six Sigma for Good book series
Florida Atlantic University Executive MBA Program
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Sep 8, 2024 • 15min
E109: The Lean Journey at Rockwell Collins with Clay Jones - Part 6
This is the final part of the 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program.
In this clip, he answers audience questions:
1) How to immerse Lean into the culture?
2) How is he going after employee healthcare costs? (asked by George Koenigsaecker)
3) What are the biggest barriers he is concerned about?
In his answers, he mentions the importance of coaching and mentoring, but also discusses the classroom and virtual training courses, knowledge management and the Communities of Practice program.
He also shares some of the work that Rockwell Collins has done to drive Lean into healthcare (including a grant program I worked on).
Finally, he stressed the importance of not being complacent, always looking for waste and reducing cost of nonconformance, and the strive for continuous improvement. I also share my thoughts on what happened to the Lean program when Kelly Ortberg (now the Boeing CEO and President) took over for Clay in 2013.
You can watch the entire video at http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation
Additional Links
Clay Jones Wikipedia page
Kelly Ortberg Wikipedia page
George Koenigsaecker
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

Sep 5, 2024 • 12min
E108: The Lean Journey at Rockwell Collins with Clay Jones - Part 5
This is part 5 of the 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program.
In this clip, you'll hear him discuss the 5 lessons learned from the first 8 years of the Lean journey at Rockwell Collins (1998 to 2006).
Senior Leadership alignment
Managing change and resistance
Course correction when needed
Implement Value Stream Mapping first
Ask for help
"If leadership isn't driving your Lean transformation, don't even start. It's like teaching a pig to talk. You're wasting your time, and you're annoying the pig" - Clay Jones
He shares some impressive results that were partly due to Lean implementation. Stock price increase of 260%, return on investment capital from 21% to 38%, sales almost doubled from $1.8B to $3.5B, net income over 80%, both business units over 18% operating margin, along with the traditional improvements to on-time delivery, customer acceptance (quality) and sales per employee.
You can watch the entire video at http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com

6 snips
Sep 2, 2024 • 18min
E107: The Lean Journey at Rockwell Collins with Clay Jones - Part 4
This is part 4 of the 2006 speech given by Rockwell Collins CEO, Clay Jones. I worked at Rockwell Collins from 1999-2017, and was heavily involved in the Lean Electronics program.
In this clip, you'll hear him discuss how they expanded on the Core Process Optimization efforts to move to Lifecycle Value Stream Management. This allowed them to address the wastes in the handoffs between major processes. The VSM roles required them to change their roles, metrics, behaviors and cost allocations.
"Lean is a journey, not a destination" - Clay Jones
He also shares how they expanded Lean into innovation and creative processes like Engineering, Design and Development and Research. This broke the stereotype that Lean was only for manufacturing. The standardization of these major processes helped bring some consistency and efficiency to how a product was proposed, funded, managed, designed, transitioned and supported.
He also reiterated the importance of knowledge management in capture information and disseminating it across the organizations and value streams.
You can watch the entire video at http://techtv.mit.edu/videos/16101-leading-rockwell-collins-lean-transformation
If you're interested in taking a Lean, Green Belt or Black Belt course, consider these self-paced affordable courses from OpEx Training: https://www.leansixsigmadefinition.com/shop/
Need help in your organization, or want to discuss your current work situation? Let's talk! Schedule a free support call
Podcast Sponsor: Creative Safety Supply is a great resource for free guides, infographics, and continuous improvement tools. I recommend starting with their 5S guide. It includes breakdowns of the five pillars, ways to begin implementing 5S, and even organization tips and color charts. From red tags to floor marking; it’s all there. Download it for free at creativesafetysupply.com/5S
BIZ-PI.com
LeanSixSigmaDefinition.com
Have a question? Submit a voice message at Podcasters.Spotify.com


