What Ford and the UAW Really Learned from Japan: Listening, Respect, and a Better System

What Ford and the UAW Really Learned from Japan: Listening, Respect, and a Better System

The blog post

When Ford and UAW leaders traveled to Japan in 1981, they expected to find better machines, tighter processes, and technical secrets. What they found instead was something far more powerful: a management system built on listening, trust, and respect for people.

In this Lean Blog Audio episode, Mark Graban revisits the 1981 Ford–UAW study trip to Toyota, Nissan, and Mazda through the reflections of Don Ephlin, one of the UAW’s most thoughtful leaders. The visitors didn’t discover better workers or superior discipline — they discovered a system that expected people to think, speak up, and improve the work.

From the meaning of the andon cord to the lessons that later shaped NUMMI, this episode explores why Lean was never really about tools — and why respect, listening, and psychological safety remain the foundation of sustainable improvement today.

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Still Learning: A Live Event with Elisabeth Swan on May 7

Still Learning: A Live Event with Elisabeth Swan on May 7

Blog post with linksThree years ago, The Mistakes That Make Us came out. Around the same time, Elisabeth Swan published Picture Yourself a Leader. Both books' third birthdays felt like a decent reason...

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What a Brandi Carlile Concert Teaches About Practicing Continuous Improvement

What a Brandi Carlile Concert Teaches About Practicing Continuous Improvement

Read the blog postTL;DR: A sound check, live song requests, and a naming regret — what watching Brandi Carlile perform taught me about specific problem-solving, vulnerability, and continuous improveme...

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What Deming and Fujio Cho Agreed On: Stop Demotivating People

What Deming and Fujio Cho Agreed On: Stop Demotivating People

The blog postTL;DR: Deming and Toyota's Fujio Cho asked the same uncomfortable question: why do management systems destroy motivation in people who started out wanting to do good work? The answer poin...

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Create Your Own Lean System — But Don’t Lose Sight of These Three Things

Create Your Own Lean System — But Don’t Lose Sight of These Three Things

Read the blog postTL;DR: In a 1993 speech, Toyota leader Fujio Cho said organizations can create their own Lean systems, but success depends on three principles: leaders going to the gemba, asking “wh...

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Building an AI Chat Assistant From My Lean Hospitals Book

Building an AI Chat Assistant From My Lean Hospitals Book

The blog postWhat if a book could become an interactive coach instead of a static reference?In this episode, Mark Graban shares a behind-the-scenes look at his experiment turning the award-winning boo...

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Inside the 1987 NUMMI Management Practices Executive Summary: Why Leadership Mattered More Than Lean Tools

Inside the 1987 NUMMI Management Practices Executive Summary: Why Leadership Mattered More Than Lean Tools

The blog postIn this episode, I explore the 1987 NUMMI Management Practices Executive Summary — a confidential General Motors report that documented why the joint venture between GM and Toyota was suc...

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