Mark DeLuzio discusses the intangibles that made all the difference to the success of the Danaher Business System. He also discussed the main ingredients of DBS, the 5Ps: Purpose, Principles, People, Plan, Process.

Some metrics were never meant to survive in a Lean world. OEE and absorption accounting might sound smart on paper, but they push the exact behaviors that wreck flow, bury quality issues, and inflate inventory. The result? A system that looks efficient but delivers chaos.

Mark DeLuzio breaks down how these outdated measures keep companies locked in batch production and bad habits. He shares firsthand stories from the factory floor and the boardroom, including a jaw-dropping moment with a CFO who learned the hard way that ROI is not a reason to keep machines running at all costs.

This episode is for anyone tired of playing metric games that look good in reports but hurt performance where it matters. If you’ve struggled to explain why certain KPIs feel off in a Lean environment, you’ll walk away with clear examples and a smarter alternative to measure what actually matters.

Replay from our live April 7 webinar.

Most Lean initiatives stall because leaders chase tools instead of building capability. In this rare unfiltered session, Mark DeLuzio teams up with seasoned transformation veteran Mark Forkun for a blunt conversation on the realities of Lean, why most organizations fake it, and what it takes to get results that last.

From the hidden failure of matrix org charts to the silent sabotage of cost accounting, this webinar replay is a wake-up call for anyone tired of surface-level improvement. You'll hear how Toyota's true strength isn't what's on the walls, but what's in the minds. You'll also get hard-won insight on problem solving, value stream management, and the dysfunction of Lean "audits" that create motion without impact.

Plus, Mark Forkun shares a preview of his new book and the habits he believes matter most for sustaining Lean results.

• 00:02:10 Why there’s no silver bullet in Lean
• 00:04:30 What you don’t see is what matters — Culture, mindset, and invisible systems > visible tools.
• 00:07:40 Value stream management vs. functional silos
• 00:13:00 How Lean accounting drives better decisions — Traditional cost systems sabotage transformation.
• 00:24:00 Cost of poor quality is hidden everywhere — Why finance must stop tracking irrelevant metrics.
• 00:25:10 Lean ≠ TPS
• 00:33:00 Standard work and problem solving
• 00:47:00 Philosophy and principles lead the way
• 00:54:00 Why Gemba boards fail and audits backfire — Most Lean efforts are theater, not transformation.
• 01:00:00 Tech without waste elimination = faster waste — AI and ERP as enablers, not solutions.

In this episode, Mark DeLuzio talks about Lean Horizons' Managing Director Jon Boucher discussing the span of control necessary for problem-solving. In particular, Mark and Jon address the following:

• What is span of control, and why is it important for any lean journey
• Problem Solving – What is the definition of a problem?
• What is meant by standards? How do you begin, how deep do you go, and what is the timeline?
• What is the purpose of a line? (to expose the problems)
• Who "owns" problem-solving? What is the role of the operator?

In this episode, Mark DeLuzio talks about why Lean/CI people are not being listened to and gives sage advice as to how to reverse this trend.

Do you want to get the attention of leadership? Then you need to speak their language. In this episode, Mark DeLuzio discusses FCF %NI and why this measure is key to a successful Lean transformation.

You will never transform your company by point kaizen alone. Learn why traditional Japanese consultants were not enough in order to propel Danaher into a space all by themselves. Kaikaku (radical change) was a hallmark of Danaher’s Strategy Deployment process.

Mark discusses how companies develop On-Time Delivery KPIs (OTD) that do not reflect the customer's needs. Learn how Mark calls these "Watermelon KPIs" – GREEN on the outside and RED on the inside. Do your OTD metrics truly drive customer satisfaction?