Assembly Magazine logo
search
Ask ASSEMBLY AI
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Assembly Magazine logo
  • TRENDS
    • Ask ASSEMBLY AI
    • Trends
    • News
    • New Products
  • INDUSTRIES
    • Aerospace
    • Appliance
    • DFMA Assembly
    • Medical Devices
    • Green Manufacturing
    • Lean Manufacturing
    • Machinery Assembly
    • Electronics Assembly
    • Automotive
  • TECHNOLOGIES
    • Adhesives & Dispensing
    • Assembly Presses
    • Automated Assembly Systems
    • Manufacturing Management
    • Manufacturing Software
    • Motion Control
    • Screwdriving & Riveting
    • Robotics
    • Test & Inspection
    • Plastics & Metal Welding
    • Wire Processing
    • Workstations
  • AUTONOMOUS & ELECTRIC MOBILITY
    • AEM Magazine Archives
    • Autonomy
    • Electrification
    • Mobility Services
    • Assembly & Testing
    • AV/EM News
  • MEDIA
    • Ask ASSEMBLY AI
    • Podcasts
    • Assembly News Now
    • Assembly TV
    • Webinars
    • eBooks
  • EVENTS
    • Calendar
    • The ASSEMBLY Show
  • MORE
    • Exclusives >
      • Plant of the Year
      • Capital Spending
    • Buyers Guide >
      • Supplier Insights
    • Classifieds
    • Featured Products
    • Newsletters
    • Store
    • White Papers
    • Columns
    • Sponsor Insights
  • INFOCENTER
    • Assembly & Test Solutions
  • EMAGAZINE
    • eMagazine
    • Archive Issues
    • Advertise
    • Contact Us
    • Sign Up
Columns

Leading Lean: Are YOU Leading Lean?

By Jamie Flinchbaugh
July 1, 2006
In the past 6 months we've covered topics ranging from 5S to lean principles. Now it's time to talk about what's needed to turn words into action-leadership.

What is leadership? Specifically, what is lean leadership? In business today, leadership and management have become synonymous, losing all meaning in the process. Effective leadership is vital, but overuse of the word has done a disservice to the importance and rarity of good leadership, and to the nature and challenges of management.

Leadership and management are distinct concepts. Management is maintaining current reality. It is operating the system, making decisions, allocating resources, providing direction and solving problems. Leadership is moving to the ideal state. It comprises all the conversations, activities and insights that move an organization and individuals to a new level. The late D. Wayne Calloway, former head of Pepsi, said, "As it turns out, plants and dollars can be managed, but people expect leadership."

Leadership of lean is complicated, messy and challenging. Leadership is all the more important with lean, because lean is about changing the way people think, act and even talk. Remember, a lean culture spreads through the organization one heart and mind at a time.

A single model for the ideal lean leader does not exist, but herewith, I offer my 1-minute course on leading lean. It is based on answering three questions drawn from the example of a real client, a lean champion asked to move a reluctant organization forward, whom we shall refer to as "Frank."

QUESTION 1. What is your own personal vision of what must happen?

Answering this question isn't easy. It requires a deep understanding of your current reality, plus reflection, analysis and an image of the ideal state.

Frank believed that to move this company forward, he would need to get the five top leaders to sit down regularly to discuss the operations of the company. They would have to learn, and discuss issues related to having a common way of operating the business.

QUESTION 2. What are you willing to do to achieve this?

This is the gut-check question. What's your personal risk tolerance, or personal willingness to take a chance? Frank knew that without getting these five top leaders on the same page, the rest of the organization would flounder in confusion, and he would ultimately fail at his job. The answer to this question is different for everyone; in this case, Frank knew that he had to get the commitment from each individual or quit. This was now a legitimate negotiating point with the executives who wanted the organization to move forward, despite their behaviors.

QUESTION 3. What stands in the way of you taking that action today?

Franklin Roosevelt, a man who faced many real obstacles, said "The only limit to our realization of tomorrow will be our doubts of today." Frank had doubts about his ability to have this conversation with each of the executives, and needed help on how to effectively position the discussion.

So Frank practiced, with feedback, until he got it right. This gave him the confidence to go forward, and he succeeded in winning their commitment to working together.

That's it: the one-minute lesson on lean leadership. Sound simple? It is. But that does not mean it is easy. It wasn't easy for Frank. It just seems that way. We all have the same number of seconds in the day. Will you use YOUR seconds to lead lean?

Jamie Flinchbaugh is a founder and partner of the Lean Learning Center in Novi, Michigan, and the co-author of The Hitchhiker's Guide to Lean: Lessons from the Road. He shares his successful and varied experiences of lean transformation as a practitioner and leader through companies such as Chrysler and DTE Energy. He also has a wide range of practical experience in industrial operations, including production, maintenance, material control, product development and manufacturing engineering. Jamie is a graduate fellow of the Leaders for Manufacturing Program at the Massachusetts Institute of Technology, where his research thesis was on implementing lean manufacturing through factory design. He also holds a B.S. in Engineering from Lehigh University in Bethlehem, PA, and an M.S. in Engineering from the University of Michigan. To contact Jamie directly, go to the Web site www.leanlearningcenter.com.

Links

  • www.leanlearningcenter.com

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Jamie Flinchbaugh is a founder and partner of the Lean Learning Center in Novi, MI, and the co-author of The Hitchhiker’s Guide to Lean: Lessons from the Road. He is a coach and consultant to executives and practitioners in industries ranging from hospitals to high technology. You can follow his writings on his blog at www.jamieflinchbaugh.com. To contact Jamie directly, go to the web site www.leanlearningcenter.com.

Recommended Content

JOIN TODAY
To unlock your recommendations.

Already have an account? Sign In

  • Made in the U.S.A.

    Consumer Products Manufacturing: Made in the USA

    Supply chain lessons learned during the coronavirus...
    Automated Assembly Systems
    By: Austin Weber
  • Best Practices for Press-Fit Assembly

    Best Practices for Press-Fit Assembly

    In manufacturing, ironclad formulas for success are hard...
    Assembly Presses
    By: Jim Camillo
  • aem0523leader-tesla1.jpg

    Tesla Rethinks the Assembly Line

    Engineers at Tesla Inc. have developed a new process that...
    Assembly and Testing
    By: Austin Weber
Manage My Account
  • eMagazine Subscription
  • Assembly Newsletters
  • Online Registration
  • Subscription Customer Service
  • Manage My Preferences

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the ASSEMBLY audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of ASSEMBLY or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • ultrasonic welding
    Sponsored bySonobond Ultrasonics

    Engineering Efficiency in High-Performance Assembly: How Ultrasonic Welding Enhances Throughput, Reliability and Quality

  • UV curing system
    Sponsored byDymax

    Why UV Intensity Alone Doesn’t Define Curing Performance

  • wooden pallets
    Sponsored byLEAN Manufacturing Products

    Eliminating Waste on the Shop Floor: Applying Lean Principles to Improve Manufacturing Efficiency

Popular Stories

ASSEMBLY News Now, episode-30: Volvo Redesigns EV Manufacturing

Volvo Redesigns EV Manufacturing

Boeing CEO Kelly Ortberg announces 1 billion investment

Boeing Plans $1 Billion Wichita Investment, Workforce Training Center

GE Appliances Worker on Line

GE Appliances Expands Factory AI With 800 Gemini Enterprise Agents

Watch the latest episode of ANN now!

Events

July 24, 2025

From Shop Floor to CFO: How Manufacturers Are Closing the Loop Between Operations and Finance

On Demand Learn how manufacturers are bridging the gap between the shop floor and ERP systems to gain real-time visibility, streamline operations, and kick-start digital transformation—without waiting years.

Sponsored by:

PicoStratusGreen
July 30, 2025

Buffer Analysis and Design Fundamentals for Manufacturing Excellence

On Demand In this presentation, Dr. Herman Tang shares practical insights from his industry experience and research on buffer management in manufacturing operations.

View All Submit An Event

Poll

Difficult Assembly Processes

Which assembly process gives you the most difficulty?
View Results Poll Archive

Products

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

Manufacturing Cost Policy Deployment (MCPD) Profitability Scenarios: Systematic and Systemic Improvement of Manufacturing Costs

See More Products
Register for webinar - Modernizing Automotive Assembly: Why Upgrading Legacy MES is a Business Imperative

Related Articles

  • Leading Lean: Do You Know Your Control Points?

    See More
  • Leading Lean: Lean and Human Resources

    See More
  • Leading Lean: Bring Lean to Your Sales Team

    See More

Related Products

See More Products
  • achieving

    Achieving Excellence Through Lean Manufacturing: A Lean Leader’s Journey

  • Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line

  • pocket.jpg

    The Lean Six Sigma Pocket Toolbook

See More Products

Related Directories

  • Lean Manufacturing Products

    Lean Manufacturing Products LLC is a leading provider of innovative solutions designed to enhance operational efficiency and productivity in various industries. Specializing in lean manufacturing principles, we offer a comprehensive range of high-quality products, including racking systems, safety equipment, and modular storage solutions. Our mission is to help companies streamline their processes, reduce waste, and create more effective work environments. With a commitment to exceptional customer service and cutting-edge design, Lean Manufacturing Products LLC partners with businesses to implement best practices that drive success and foster continuous improvement.
×

Never miss the latest news and trends driving the manufacturing industry

Stay in the know on the latest assembly trends.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Manufacturing Division
    • Store
    • Want More?
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • Newsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2026. All Rights Reserved BNP Media, Inc. and BNP Media II, LLC.

Design, CMS, Hosting & Web Development :: ePublishing