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Are you looking to build brilliant processes in your organization?   Start with DOWNTIME.   This acronym stands for   +Defects +Overproduction +Waiting +Non-Utilized Talent +Transportation +Inventory +Motion +Extra Processing   It's a mnemonic used in Lean Six Sigma to represent the 8 types of waste.   Being able to see them is always the first step.   Here's a breakdown by Nilson to identify the 8 wastes of Lean: (give him a follow)

Quality 101: If you can't measure something, you can't improve it. This principle is foundational in many fields +Healthcare +Manufacturing +Scientific Research +Quality Management +Business Performance +Personal Development Here are 7 quality tools for process improvement: 1/ Pareto Chart 2/ Histogram 3/ Flowchart 4/ Control Chart 5/ Scatter Diagram 6/ Check Sheet 7/ Ishikawa Diagram The wisdom is simple but profound: Without a way to objectively measure something, you're essentially working in the dark.

Leaders face a constant choice.   Trust gut feelings or follow the numbers?   But here's the thing -    It doesn't have to be either/or.   True leaders know when to use each approach.   Data shines to:   +reveal patterns across large datasets +minimize cognitive biases +provide objective benchmarks +quantify improvement over time   Yet intuition matters:   +during rapid-response situations +for novel challenges with no historical data +when incorporating qualitative factors +for detecting subtle signals data might miss   The next time you face a tough decision, ask yourself:   +What does the data tell me? +What is my experience suggesting? +Where do they align or conflict? +Which approach best fits this specific situation?   The real magic happens when you integrate both:   Using data to inform your intuition. And intuition to guide what data is collected.   TL;DR   Use data to sharpen intuition.   Let intuition guide which data matters.   *** P.S. How do you balance data and gut feelings in your decisions?

One thing you should do to save a struggling business: Expose the problems. People who speak up about problems seem to be troublemakers. But they are heroes. Let me draw you an analogy to explain why: ++The River of Waste+++ It's a common metaphor used in Lean Manufacturing. It's about the importance of reducing inventory to expose problems. Imagine a river where... +the water level is the amount of inventory +the boat is your organization +the rocks are the problems When the water level is high, the rocks are hidden. ↳ Process looks smooth As the water level goes down, the rocks resurface. As encountering a rock, you can… -go around the rock -run into the rock -go over the rock -remove the rock Traditional approach: ↳ Raise the water level, and go over the rock. Lean approach: ↳ Lower the water level to expose the rock. Don't throw resources. Reduce inventory levels to expose the problems. Then, tackle them one at a time. *** TL; TR Hiding issues can only lead to bigger disasters. Look for the big rocks. Pick no more than 3 or 4. Then, remove them. One by one. No BS. *** Follow Ivan Carillo for more.

Procrastination isn't laziness. It's self-harm.   And applying Kaizen is the only way you can get over it.   Procrastination is derived from the Latin verb 'procrastinare' - putting off something until tomorrow.   Kaizen principles are poles apart, and you can use them to combat procrastination.   Here are 5 key differences:   1/ Core Behaviour   Procrastination: ➟ Postponing important tasks despite knowing consequences Kaizen: ➟ Making small, consistent improvements right now   2/ Timeframe   Procrastination: ➟ Sacrificing future success for present comfort Kaizen: ➟ Investing small efforts for cumulative future benefits   3/ Decision Pattern   Procrastination: ➟ Emotional decisions over logical ones Kaizen: ➟ Process-oriented decisions focused on CI   4/ Result   Procrastination: ➟ Missed deadlines, increased stress Kaizen: ➟ Muda silent killer   5/ Feedback Loop   Procrastination: ➟ Each delay makes the next one easier to justify Kaizen: ➟ Each improvement builds momentum for the next Improvement doesn't require perfect conditions.  It requires consistent, immediate action. No matter how small.

Your company isn't gonna go out of business because of AI.   It's gonna wipe out because another company used AI.   Master AI to keep your CI organization ahead in 2025.   Here's a breakdown:   KEY APPLICATIONS   1/ Advanced Analytics    ↳ AI analysis of production data to identify bottlenecks  ↳ Sensor data and ML to predict equipment failures  ↳ Automated workflow improvements   2/ Smart Production    ↳ Computer vision systems for anomaly detection  ↳ Real-time quality monitoring  ↳ Less human errors   3/ Data-Driven Decision Making    ↳ Automated KPI tracking and visualization  ↳ Intelligent root cause analysis  ↳ Scenario modelling for improvement initiatives   KEY CHALLENGES   1/ Cultural Resistance    ↳ Traditional improvement mindsets  ↳ Resistance to data-driven decision making  ↳ Management buy-in challenges   2/ Data Infrastructure    ↳ Siloed information systems  ↳ Data collection standardization  ↳ Analytics capability gaps   3/ Technical Challenges    ↳ Cybersecurity risks  ↳ System reliability  ↳ Integration complexity   Remember:   The biggest room in the world is the room for improvement.   But if you're still relying on old CI methods, you're doing it wrong.   There's no question about that.

The Blueprint for Self-Improvement Credit to my friend César Solís (give him a follow) Original post below: For years, I thought self-improvement required a grand gesture. A drastic transformation, a new job, or a big life change. But real growth doesn’t come from one big step. It comes from small, consistent actions you build daily. Here are 15 simple steps that can help you grow into your best self: 1. To learn faster, make the process: Fun ↳ Find one way to make your learning fun today. 2. To understand yourself: Write ↳ Spend 5 minutes journaling every morning. 3. To improve your mood: Exercise ↳ Go for a 20-minute walk daily. 4. To understand the world better: Read ↳ Read one page before checking your phone. 5. To think more clearly: Meditate ↳ Meditate for 5 minutes using an app like Headspace. 6. To help people: Help yourself ↳ Ask yourself: “Am I pouring from a full cup today?” 7. To grow faster, make sure to stay: Consistent ↳ Track one habit with a daily checklist. 8. To stay energized, prioritize: Sleep ↳ Set an alarm to remind you to wind down. 9. To build deeper connections: Listen ↳ Ask someone: “What’s exciting in your life right now?” 10. To overcome challenges: Adapt ↳ When things go wrong, ask: “What’s my next move?” 11. To strengthen your focus: Practice mindfulness ↳ Pause and count to 3 before responding. 12. To create lasting change: Start small ↳ Focus on one small change at a time. 13. To make better decisions: Pause ↳ Sleep on big decisions before acting. 14. To achieve more: Simplify ↳ Write your top 3 priorities and stick to them. 15. To gain confidence: Take action ↳ Say: “I’ll figure it out” and take the first step. Growth doesn’t have to be complicated. It’s the small, intentional steps that add up to big transformations. P.S. Which step will you start with today? Share below *** Follow me Ivan Carillo for more content like this

Organizations treat Poka-Yoke as an afterthought.   It should be the first principle of process design.   Poka-Yoke is a Japanese term that means "mistake-proofing".   It refers to techniques designed to prevent, detect, and correct errors during a process.   Shigeo Shingo introduced the concept in the 1960s as part of the Toyota Production System.   Here are 5 reasons why Poka-Yoke is crucial in manufacturing and beyond:   1/ Error Prevention   Poka-Yoke approaches transform how organizations prevent mistakes.   They move beyond traditional inspection methods to proactively design out potential failures.   *** 2/ Cost Reduction   Mistake prevention translates to economic advantages.   By eliminating errors before they occur, organizations can reduce   +warranty claim costs +rework expenses +scrap rates   *** 3/ Quality Assurance   Poka-yoke principles transcend traditional QC methodologies.   These principles ensure that products are made according to specified quality standards and requirements.   They embed quality directly into process design.   *** 4/ Workforce Protection   Poka-yoke extends beyond product quality to human safety.   For example, safety mechanisms that prevent machinery from operating when guards are not in place.   *** 5/ Process Simplification   Poka-yoke methods often simplify systems and processes.   They can lead to:   +faster setups +work easy to do +clearer instructions +low training requirements *** Continuous Improvement is 90% mindset and 10% toolset. While you focus on developing your mindset, we’re working hard to build KaizenHQ! KaizenHQ will handle your toolset from 0 to 100%. Do you wanna be the first to know when we launch it in Q3’2025? Join 785+ CI leaders on the waitlist here: https://lnkd.in/dJdUqhR3

Uncomfortable reality: If you stay in your comfort zone, that’s where you will fail. You cannot find your true essence there. Set personal goals that push your limits, be it hiking or public speaking. Work backwards from your goals and define the single steps you’ll need to take. If you turn these steps into habits, you’ll be far more likely to be successful. Success isn’t a comfortable procedure. Things are going to go wrong along the way. So, learn how to deal with it. Failure is a key part of the process and that’s why success is a very uncomfortable thing to do. Get comfortable being uncomfortable if you ever want to be successful. *** P.S. I'm pushing myself out of my comfort zone by building our first digital asset. KaizenHQ is coming in Q3'25! If you wanna grow your CI organization with an all-in-one workspace designed to +save you time +run more Kaizen initiatives +and drive more revenue Join the waitlist here: https://lnkd.in/dJdUqhR3

Digitalizing Poka-Yoke Level: PRO Poka-Yoke is a Japanese term that means "mistake-proofing". It refers to any mechanism helping an operator avoid mistakes by preventing, correcting, or drawing attention to human errors as they occur. Visual aids can add value to your workstations through: +digital storage and distribution of new procedures +guidance for your operators with projected AR +easier onboarding of new workers +elimination of paper manuals +enhanced quality control +flexible production Visual aids support operators in making the right judgement call.

6 principles to make the best companies even better:   (one percent at a time)   Kaizen is a systematic approach where all employees work together to make small, incremental changes.   The term combines two Japanese words:   "kai" (change) + "zen" (good)   Literally meaning "change for the better."   Here are 6 Kaizen principles to skyrocket your organization:   1/ Question best practices   Best practices often become sacred cows that hinder progress (even when they're no longer optimal for current conditions)   The most dangerous phase in a business is “we've always done it this way”   Don't justify past methods.   *** 2/ View problems as opportunities   The problem itself isn't the issue. The issue is your attitude and what you do as a result.   Seize the growth opportunity.   *** 3/ Embrace hardship   Being constant and patient will lead you to outperform the eager individuals who burn bright and fast.   Difficult situations force deeper thinking. And they take as long as they take.   Slowly can be the fastest way to get where we want to be.   *** 4/ Choose simple solutions   People often accept the complex solution to a problem without considering the simpler ones at all.   Use the simplest solution, which ticks all the boxes.   *** 5/ Be data-driven   Deming once said: "In God we trust. All others must bring data."   Measure improvements objectively.   *** 6/ Creativity > Capital   Prioritize creativity over capital.   Creative approaches often yield more sustainable solutions.   Use wisdom before spending money.

Reducing Setup Costs   Level: PRO   Single Minute Exchange of Die (SMED) is a Lean method for reducing inefficiencies in a process.   It provides a rapid way of switching your production from product A to product B.   The ultimate goal is to reduce the changeover time from hours down to < 10 mins   (so, you can react to unexpected variations in demand)   KEY BENEFITS:   +Higher OEE +Smaller lot sizes +Greater flexibility +Lower operative costs +Lower skills requirements +Reduced uneven flow (Mura) +Standardized changeover procedures +Better responsiveness to customer demand   There is a paradigm shift with SMED:   Setup time is no longer regarded as a constant, but as a variable.   P.S. Traditional nut-and-bolt assemblies are outdated.   One-touch fasteners make your changeovers quicker and easier without the use of tools

KPIs are improving, but your people are burning out.   Welcome to the paradox of Kaizen under toxic leadership.   In some boardrooms of top companies now, executives are celebrating as metrics climb upward.   -Productivity is up 15% -Cycle times have been slashed -Defect rates have dropped to historic lows   Yet a different story unfolds on the factory floor…   -Burnout rates are soaring -Some talents are submitting resignations -Others move through their days with hollow eyes   This is the twisted reality when Kaizen falls into the hands of toxic leaders.   Here are 7 warning signs you're doing Kaizen wrong:   1/ No joy   Teams hit targets but exhibit no joy in their daily work.   Kaizen feels like a burden rather than an opportunity for growth.   2/ One-way communication   Kaizen ideas come only from managers, never from frontline staff up.   The wisdom of those closest to the Gemba is ignored.   3/ Problem hiding   People hide problems rather than exposing them to collaborative solving.   Fear of punishment is the norm.   4/ Kaizen-phobia   People avoid using CI terms in everyday conversation.   Efficiency, optimization, and process review are all terms triggering visible anxiety.   5/ Quiet quitting   Your high performers are disengaging (or secretly updating their resumes)   Those with options are planning their exits rather than their contributions.   6/ Metrics without meaning   Numbers improve while underlying realities worsen.   Short-term gains mask long-term damage to systems.   7/ Chasing numbers while ignoring human costs   People become expendable resources in the pursuit of better statistics.   *** If you recognize these red flags, it's time to +reset your leadership approach +reclaim the authentic spirit of Kaizen   PS. Repost this to help leaders in your network And follow me, Ivan Carillo, for more

How to implement Poka-Yoke within your manufacturing in 6 simple steps {without spending $100k+ on consulting}:   Poka-Yoke is a powerful Lean manufacturing tool.   It helps prevent errors and defects by designing processes and equipment that make mistakes impossible or immediately detectable.   Here's a 6-step framework to improve your production:   1/ Identify critical processes and potential errors   Where errors or defects can occur?   Conduct a thorough analysis of each process step.   Identify the potential errors that could lead to defects or quality issues.   Tools: Process Mapping, RCA or FMEA. ***  2/ Prioritize areas for poka-yoke implementation   Once you have identified the potential errors, prioritize the areas where poka-yoke implementation will have the most significant impact.   Tools: Pareto charts, histograms, or control charts. Key Factors: error frequency & severity, implementation costs. *** 3/ Design poka-yoke solutions   Identify poka-yoke solutions that can prevent or detect errors at the source.   There are several types of poka-yoke solutions, including:   +Control Poka-Yoke +Warning Poka-Yoke +Shutdown Poka-Yoke   Choose the appropriate poka-yoke solution based on your requirements. ***  4/ Train and educate employees   Provide comprehensive training to all employees involved.   Encourage employee involvement. Gather their feedback as implementing the solution.   Your employees must understand the importance of the poka-yoke solutions. *** 5/ Monitor poka-yoke solutions   Implement the solutions in the critical areas you identified.   Closely monitor the implementation phase. Gathering operators' feedback is key.   Make feedback-driven adjustments to your solutions. ***  6/ Sustain and continuously improve   Poka-yoke implementation isn't a one-time effort. It's continuous improvement.   Review the effectiveness of your solutions regularly.   Identify opportunities for further improvement or expansion to other processes.   Remember to celebrate successes. *** TL;TR:   6-step framework to implement Poka-Yoke:   Identify key processes & errors Prioritize powerful areas Design poka-yoke solutions Train & educate your employees Monitor your poka-yoke solutions Sustain and continuously improve   P.S. If you enjoyed this, repost it for your network and follow me for more.

Harsh truth: Reacting is not improving. Credit to Jose Augusto Guillermo Arnesen (give him a follow) Original post below: Most CI and ops leaders react to problems and call it progress. But fixing issues as they happen is not the same as solving them for good. Without a structured approach, the same problems keep returning. Here’s how to integrate key CI tools throughout the week to drive real, sustainable improvement: Monday – Plan (Kick Off PDCA & Set Priorities) → Identify improvement opportunities from WK-1 → Use Pareto Analysis to focus on high-impact issues → Define the problem, objectives, and success metrics Tuesday & Wednesday – Do (Implement & Observe) → Execute small-scale process improvements → Conduct Gemba Walks to validate data insights → Gather real-time feedback from operators Thursday – Check (Analyze & Review Progress) → Assess early results from implemented actions → Use Run Charts & Control Charts to analyze trends over time → Compare results vs. expectations → Identify gaps or unintended side effects Friday – Act (Standardize & Plan Next Steps) → If successful, document & standardize the improvements. → If needed, refine the approach for the next cycle → Set priorities for the next PDCA iteration Not every factory can sustain a weekly problem-solving cadence. But remember: Structured improvement is always possible. Start monthly Refine the approach. Adjust based on what makes sense for your team. *** Follow me, Ivan Carillo, for more content like this

One cardinal rule: Slowly is the fastest way to get to where you want to be. We run because we are told this is the only way. Faster is better. But where we're running to? Slowness isn't a weakness. And there is nothing wrong with you. Take a moment. Enjoy the view. You are allowed to +go at your own pace +be slow and messy +make mistakes Time isn't a thing to run from. Be the tortoise, not the hare.

6 must-know Japanese techniques to upgrading your life Quick-reference guide by Rob Dance: If you are serious achieving your full potential,   You need to be aware of these 6 powerful techniques:   Ikigai ↳ Make sure you have a purpose in life—a reason to wake up each morning. Choose something that aligns with your strengths and passions, and the needs of the world.   Kaizen ↳ Focus on small improvements every day. Aim to become 1% better daily.   Shoshin ↳ Always approach life with a beginner's mindset. Stay curious and open-minded. Don’t worry about being perfect or having all the answers. Just be open to learning and trying new things.   Wabi-sabi ↳ Find beauty in imperfection. Recognise that nothing in life is perfect, and the imperfections are what make life unique.   Gaman ↳ Have dignity during tough times. Meet hard times with emotional maturity and self-control. Practise patience, perseverance, and tolerance.   Oubaitori ↳ Everyone has unique strengths, weaknesses, and life experiences, each with a distinct journey. Focus on your personal growth and development, rather than comparing yourself to others.   Start integrating these techniques into your daily life, And watch how they transform your mindset and growth. P.S. Which one is your favourite? *** Repost to help your network And follow Ivan Carillo for more content like this

VSM isn't just a Lean tool.     It's the key to your business success.    The main goal of a business is to provide outstanding value at the lowest price.    In line with this goal, Value Stream Mapping aims to show you where you can reduce waste.    VSM visualises your operations from material inputs to customer delivery.     Here are 5 simple steps to create your Value Stream Map:    Step 1. Pick a Product Family    Recognize the value stream from your customer perspective.    Select a large-quantity and high-revenue product family.  Focus on reducing cycle times for your best sellers.    It's crucial to maximize the gains.  __    Step 2. Build your team    Assign a dedicated team leader.  Pick subject matter experts from key departments.     Make sure they know enough about the product and VSM.  __    Step 3. Figure out your customer demand    Check your production history.    Figuring out your customer demand is critical to calculate your takt times.  __    Step 4. Map the material flow    Map the journey that materials embark on, from receive to customer delivery.    It helps identify waste by analyzing each step of material handling.     Look at how the material flow is secured by operators.    At this point, key questions can be:    -What systems are in place to replenish your inventory levels?    -Do your operators have the materials they need to hand?      Then, add the collected data to this flow.  __    Step 5. Map the information flow    How does information move through the value stream from the initial request to order delivery?    Capture how the information goes through your organization.    Pinpoint communication gaps, and enhance data flow. Video Credits: Krish Sengottaiyan __    TL;TR    5-step framework for Value Stream Mapping:    1. Pick a product family  2. Build the VSM team  3. Figure out your customer demand  4. Map the material flow  5. Map the information flow

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25 sentences every Kaizen leader must hear at least once: 1. Make problems visible. 2. Slow down to speed up. 3. Never waste a good crisis. 4. Challenge the status quo, always. 5. Culture eats strategy for breakfast. 6. Best ideas come from the frontline. 7. Transform your experts into coaches. 8. Plan, Do, Check, Act —repeat forever. 9. No blame, no judgment - just learning. 10. Problems are opportunities in disguise. 11. Simplicity is the ultimate sophistication. 12. You're judged on results, not intentions. 13. Data tells you what; people tell you why. 14. The person doing the work knows it best. 15. Without psychological safety, Kaizen dies. 16. Problem-solving skills are non-negotiable. 17. Gemba never lies; go and see for yourself. 18. Respect tradition, but don’t be imprisoned by it. 19. Your job is to remove obstacles, not create them. 20. Resistance to change is feedback, not obstruction. 21. See the invisible waste that others walk past every day. 22. A master knows when to step aside and let others grow. 23. Your credibility with the frontline is your most valuable asset. 24. The hardest part isn't implementing change—it's sustaining it. 25. Know when to strike and when to observe—timing is everything. *** Repost this to help leaders in your network And follow me, Ivan Carillo, for more