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Artwork for Why They Fail ... and the Simple Key to Success!

Why They Fail ... and the Simple Key to Success!

Kevin Clay, Master Black Belt
Lean Six Sigma
Six Sigma
Leadership
Continuous Improvement
Lean
Six Sigma Development Solutions
Shainin
Key Performance Indicators
Culture
Lean Snake Oil
DMAIC
Healthcare
Pull System
Amazon
Shainin Methodology
Yellow Belt
Toyota Production System
Cheerleading
Army
Lip Service Leadership

Tired of watching continuous improvement efforts crash and burn? So are we. "Why They Fail" dives headfirst into the brutal truth behind failed Lean Six Sigma deployments, exposing the myths, the mistakes, and the outright absurdities that plague organizations worldwide. Forget the sugar-coated success stories—we're here to dissect the disasters, from executives who think training is optional to l... more

PublishesWeeklyEpisodes23Foundeda year ago
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Artwork for Why They Fail ... and the Simple Key to Success!

Latest Episodes

Haphazard continuous improvement does not just waste money. It blinds your teams, fractures trust, and quietly sets up every practitioner you train to fail. When corporate leadership throws disconnected lean tools at isolated problems without a struc... more

YouTube

Bad cultures with bad leaders do not fix themselves. They buy their way out. A new warehouse management system. A bigger facility. An expensive digital platform. The same chaos, now running on software that costs a fortune.

In this episode of the Wh... more

Over 90% of corporate deployments fail within eighteen months. One of the most common reasons is the creation of continuous improvement silos. When process improvement is locked inside a single department or treated as a leadership checklist, cultura... more

YouTube

Gen Z Grit: How Cheer Stunts Breed Future CEOs

Welcome to another episode of Why They Fail. In this episode, we tackle an exciting angle on organizational health: gen z leadership development. Many corporate leaders wonder how the next generation wi... more

Inside Amazon: Why Process Engineers Are Guides, Not Sages

Most companies build their continuous improvement programs the wrong way. They train a single green belt or black belt and expect that one person to fix everything. However, studying Six Sig... more

Beyond the Shiny Kanban: Driving a Real EBITDA Explosion

Most business leaders believe they are running a lean operation. However, if your Kanban cards are still moving to the beat of unstable MRP lead times, you are not pulling. You are running a h... more

Why Continuous Improvement Leaders Pick Crap Projects

Most continuous improvement programs fail within 18 months. The reason is almost always the same: leadership started by avoiding bad Six Sigma projects the wrong way. Instead of using data, they ... more

Fear and Loathing: The Danger of Numerical Goals

In this episode of the Why They Fail Podcast, we take on one of the biggest traps in modern management: the obsession with numerical goals.

Dr. W. Edwards Deming warned against this decades ago in his... more

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Recent Guests

Melissa Sherman
Independent consultant and board member with over 27 years of deep operational expertise in the utility industry
Independent consultant
Episode: How Haphazard Continuous Improvement Blinds Teams
Ben Harmsen
Military veteran, Lean Transformation expert who led initiatives at Chrysler, Coca-Cola, and in underground construction
Independent CI leader
Episode: Bad Leaders, Broken Cultures: The Uncomfortable Truth
Emilio Natalio
Retired military aviator and safety officer turned Lean Six Sigma practitioner
Independent consultant; author of The Lean Six Sigma Journey
Episode: From Blackhawk Cockpits to Real Lean Six Sigma Success
Claire Clay
13-year-old rising eighth grader, Junior Miss Emerald Coast, elite Level 4-2 cheerleader
Competitive cheer and pageants
Episode: Gen Z Grit: How Cheer Stunts Breed Future CEOs
Mariam Abdalmasih
Senior Process Improvement Engineer for Amazon's London Fulfillment Operations
Amazon
Episode: Inside Amazon: Why Process Engineers Are Guides, Not Sages
Phil Ledbetter
Masterclass on raw mechanics of an authentic pull framework
Unknown (guest on show)
Episode: Beyond the Shiny Kanban: Driving a Real EBITDA Explosion
Wade Harper
Veteran CI practitioner and consultant
Independent CI Consultant; former roles at Ford, Honeywell, Allied Signal, Army deployments
Episode: Why Continuous Improvement Leaders Pick Crap Projects
John Dyer
Author of The Facade of Excellence, former VP of Continuous Improvement at Ingersoll Rand, experienced GE Six Sigma practitioner
The Facade of Excellence
Episode: Fear and Loathing: The Danger of Numerical Goals
Graham Richard
Former mayor of Fort Wayne, Indiana; introduced Lean Six Sigma to city government
City of Fort Wayne, Indiana
Episode: How Lean Six Sigma Transformed a City Govt.

Host

Kevin Clay
Host focused on Lean Six Sigma deployments and continuous improvement; public-facing thought leader on organizational capability and leadership in CI.

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Talking Points

Recent interactions between the hosts and their guests.

Gen Z Grit: How Cheer Stunts Breed Future CEOs
Q: What have you learned about teamwork and handling mistakes on the mat?
Claire shares that communication and shared accountability help the team recover quickly after a misstep, avoiding finger-pointing and promoting collective improvement.
Gen Z Grit: How Cheer Stunts Breed Future CEOs
Q: What role does routine and practice play in your success, and how does that relate to business leadership?
The host explains that repetition builds muscle memory and standard work, making teams reliable; Claire echoes that consistent practice fuels confidence and performance.
Gen Z Grit: How Cheer Stunts Breed Future CEOs
Q: How do you balance the glamorous pageant stage with the high-flying, tough world of competitive cheer?
Claire describes needing to stay organized and how her long-term goals in pageants motivate her to improve in cheer, using careful scheduling to manage both worlds.
Beyond the Shiny Kanban: Driving a Real EBITDA Explosion
Q: What is the core difference between a Kanban visualization and a true pull system?
Kanban is a tool within the pull system, not the entire system. Without aligning Kanban to a unified, end-to-end pull process and proper buffering, it becomes just a visual cue that doesn't improve flow or reduce lead times.
Fear and Loathing: The Danger of Numerical Goals
Q: Which of Deming's 14 points is most resisted by leadership today, and what is the practical daily impact of implementing that point?
Point 11, eliminating management by objectives and substituting leadership, is the most resisted. Practically, embracing leadership over numbers shifts how goals are pursued—empowering teams, reducing fear, and encouraging process-based improvements rather than blaming individuals for not hitting arbitrary targets.

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Frequently Asked Questions About This Podcast

What is This Podcast about and what kind of topics does it cover?

A hard-edged look at why continuous improvement initiatives fail, with blunt takes on leadership, culture, and the practical foundations required for sustainable results. Across episodes, listeners hear veterans and practitioners dissect doomed CI deployments, debunk myths about quick fixes, and share concrete tactics for building governance, data infrastructure, and cross-functional collaboration that actually sticks. Unique angles include real-world critiques of leadership behavior, hands-on comparisons of methods like Kanban, Shainin, and Lean Six Sigma, and accessible, story-driven lessons from government, healthcare, manufacturing, and tech environments. The show aims to help operators, managers, and consultants spot the warning signs ... more

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this podcast launched a year ago and published 23 episodes to date. You can find more information about this podcast including rankings, audience demographics and engagement in our podcast database.

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What guests have appeared on this podcast?

Recent guests on this podcast include:

1. Melissa Sherman
2. Ben Harmsen
3. Emilio Natalio
4. Claire Clay
5. Mariam Abdalmasih
6. Phil Ledbetter
7. Wade Harper
8. John Dyer

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