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Is there a first principle of Operational Excellence? If someone asked that question, many of us would probably start listing Lean concepts like respect for people, continuous improvement, flow, standard work, or problem solving. Those are all foundational to Operational Excellence, but after years of working with organizations and reflecting on what separates lasting transformations from temporary improvements, I've become convinced there is a principle that comes before ev

I've worked with many organizations over the years that invested heavily in Operational Excellence. They implemented Lean tools, improved processes, mapped value streams, conducted rapid improvement events, and introduced daily management systems. Some of those organizations achieved remarkable results that lasted for years. Others experienced improvements that slowly disappeared, even though they were using many of the same tools. That contrast caused me to ask an important

Batching and bay building feel efficient—but they quietly drive up cost, complexity, and lead time. One-piece flow does the opposite. It reveals problems fast and keeps value moving at the pace of the customer. This post breaks down why one-piece flow wins every time.

Leadership To-Do By Craig Otto | Leadership Insights In the movie Draft Day, Kevin Costner plays the General Manager of the Cleveland Browns. At the start of the movie, he writes a note to start his draft day and puts it in his pocket. The film follows him through a whirlwind of trades and developments leading up to the draft, keeping the audience guessing about his first pick. When he finally makes that pick, his decision shocks everyone—the owner, the coach, the staff, and

The Hidden Law By Craig Otto | Operational Excellence Insights Introduction: The Hidden Law Behind Decline Many organizations launch ambitious Operational Excellence (OpEx) initiatives and see impressive early wins in performance, quality, and engagement. Yet over time, those gains fade. Momentum slows. Old habits return. Why does this happen so consistently? The answer isn’t just organizational, it’s universal. According to the Second Law of Thermodynamics , everything natu

Years ago, I attended the Shingo Prize Conference in Jacksonville, Florida — an experience that completely reshaped the way I think about Operational Excellence (OpEx) . The conference itself was rich with knowledge, but the true value came not from the presentations — it came from the conversations . Between sessions, I spoke with passionate leaders, problem-solvers, and continuous improvement champions who, like me, were trying to unlock the secret to successful OpEx imple

If You Don’t Know 6S, You Don’t Know OpEx Over the years, I’ve conducted countless interviews, seeking the right candidate to help lead...

Yes, pride can absolutely get in the way of continuous improvement—especially when it takes the form of ego, defensiveness, or an...

Ask Yourself: What Are You Really Trying to Get Buy-In For? At its core, Operational Excellence isn’t just about tools, metrics, or...