Beyond ‘Fix What Bugs You’ w/ Russell Watkins | Lean Built - Manufacturing Freedom E135

Beyond ‘Fix What Bugs You’ w/ Russell Watkins | Lean Built - Manufacturing Freedom E135

In this special guest episode, Andrew sits down with Russell Watkins, co-founder of Sempai. Andrew first met Russell at the Gemba Summit in Belfast, where Russell delivered a keynote titled “10 Lightbulb Moments from Working with Toyota Japan and UK.” After cornering him at lunch with a notebook full of questions, Andrew knew this had to become a podcast conversation.

They explore:

  • What Russell learned apprenticing under a direct student of Taiichi Ohno and why he was told to “stop reading and start doing”
  • Why you don’t learn lean from books alone (but why books still matter)
  • How to actually observe work on the Gemba, and why empty workstations don’t tell the full story
  • The danger of “putting lipstick on a pig” by optimizing rework instead of eliminating the need for it
  • Why “Fix What Bugs You” works and where it falls short without strategic direction
  • A practical introduction to Hoshin Kanri (policy deployment) for small manufacturers
  • How to connect shop-floor improvements to real business needs
  • The power of visual defect analysis—even without formal data systems
  • Four simple questions that reveal the strength (or weakness) of your SOPs
  • How to handle the 20-70-10 dynamic when rolling out lean initiatives
  • Why humility and “opening the kimono” as a leader builds trust and cultural momentum

This conversation bridges the gap between the Two Second Lean community and traditional Toyota Production System thinking, offering practical insight for small and mid-sized manufacturers who want to move beyond local optimization and align improvement with long-term business survival.


Links:
The explainer on Hoshin Kanri/policy deployment that Russell mentioned

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Jaksot(153)

Why Every Machine Shop Should Take More Shop Tours | Lean Built - Manufacturing Freedom E153

Why Every Machine Shop Should Take More Shop Tours | Lean Built - Manufacturing Freedom E153

What if one of the fastest ways to improve your machine shop is walking through someone else’s?In this solo episode, Andrew shares lessons from recent shop tours, including visits to manufacturers in ...

29 Kesä 18min

Your Memory Is Not a Management System | Lean Built - Manufacturing Freedom E152

Your Memory Is Not a Management System | Lean Built - Manufacturing Freedom E152

Andrew shares how a simple magnetic tag meant to prevent a security mistake failed, not because the idea was bad, but because the process wasn’t complete. From there, Andrew and Jay explore Kanban sys...

22 Kesä 59min

The More You Optimize, The More Things Break | Lean Built - Manufacturing Freedom E151

The More You Optimize, The More Things Break | Lean Built - Manufacturing Freedom E151

A single drop of coolant shut down an overnight production run that should have been making parts for hours. Nothing crashed or was broken, yet the machine stopped, production stopped, and the schedul...

15 Kesä 47min

The Hidden Cost of Being the Easy Button (and 14 other lessons from Japan) | Lean Built - Manufacturing Freedom E150

The Hidden Cost of Being the Easy Button (and 14 other lessons from Japan) | Lean Built - Manufacturing Freedom E150

Andrew returns from Japan with 15 lessons that challenged the way he thinks about leadership, training, standards, and continuous improvement. These include thoughts on how leaders accidentally become...

8 Kesä 25min

Why Great Companies Can’t Be Copied | Lean Built - Manufacturing Freedom E149

Why Great Companies Can’t Be Copied | Lean Built - Manufacturing Freedom E149

What happens when an iconic brand starts fighting its own fans?This week, Andrew and Jay discuss Fender’s controversial cease-and-desist campaign against Strat-style guitar builders and discuss the di...

1 Kesä 56min

Six Types of Working Genius (w/ John Grimsmo) | Lean Built - Manufacturing Freedom E148

Six Types of Working Genius (w/ John Grimsmo) | Lean Built - Manufacturing Freedom E148

Jay welcomes John Grimsmo of Grimsmo Knives for a wide-ranging conversation on leadership, manufacturing culture, lean systems, and the Six Types of Working Genius assessment. Fresh off implementing t...

25 Touko 45min

Is A Good Leader A Dictator? | Lean Built - Manufacturing Freedom E147

Is A Good Leader A Dictator? | Lean Built - Manufacturing Freedom E147

Is a good leader a dictator? In this episode, Jay and Andrew wrestle with the tension between decisive leadership and collaborative growth. What starts as a customer support question turns into a deep...

18 Touko 1h

The Dangerous Line Between Confidence and Delusion in Business | Lean Built - Manufacturing Freedom E146

The Dangerous Line Between Confidence and Delusion in Business | Lean Built - Manufacturing Freedom E146

Andrew and Jay explore the tension between confidence and delusion in entrepreneurship, the challenge of scaling a company without losing yourself, and the reality that what got you here might not get...

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