{"id":3553,"date":"2025-11-25T08:00:00","date_gmt":"2025-11-25T08:00:00","guid":{"rendered":"https:\/\/gembadocs.com\/learn\/?p=3553"},"modified":"2025-11-25T08:24:28","modified_gmt":"2025-11-25T08:24:28","slug":"exploding-the-dogmas-of-lean","status":"publish","type":"post","link":"https:\/\/gembadocs.com\/learn\/exploding-the-dogmas-of-lean\/","title":{"rendered":"Exploding the Dogmas of Lean"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"3553\" class=\"elementor elementor-3553\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-2859f6d4 e-flex e-con-boxed e-con e-parent\" data-id=\"2859f6d4\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-aadd3a1 elementor-widget elementor-widget-heading\" data-id=\"aadd3a1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<p class=\"elementor-heading-title elementor-size-default\">Keynote from Tom Hughes from GembaDocs at Gemba Summit 2025<\/p>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-49c5403e elementor-widget elementor-widget-text-editor\" data-id=\"49c5403e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p>Tom Hughes, CEO of GembaDocs and author of &#8220;<a href=\"https:\/\/gembadocs.com\/learn\/books\/\">Improvement Starts with I<\/a>,&#8221; delivered a provocative keynote at Gemba Summit 2025 that challenged some of lean&#8217;s most sacred beliefs.\u00a0<\/p><p>With characteristic directness, Hughes addressed what he calls &#8220;lean dogmas&#8221; &#8211; beliefs held by groups that others are expected to accept without argument. Drawing on his experience mentoring hundreds of people through their lean journeys and moderating what he calls &#8220;without question, the best WhatsApp group for lean in the world,&#8221; Hughes has identified patterns that hold organizations back from sustainable transformation.<\/p><p>His presentation systematically dismantled common misconceptions that plague lean implementations. From the overemphasis on culture at the expense of technical knowledge, to unrealistic expectations about employee engagement, to the narrow focus on internal operations while ignoring the broader value chain, Tom made the case that many widely accepted lean principles need to be reconsidered. His final point about respect for people cut to the heart of why so many lean efforts fail before they even begin.\u00a0<\/p><p>Throughout the presentation, Tom literally exploded each dogma with enthusiastic countdowns from the audience, symbolizing the need to blow up these limiting beliefs and move forward with a more practical, sustainable approach to lean transformation.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-6776171 e-flex e-con-boxed e-con e-parent\" data-id=\"6776171\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-6569320 elementor-widget elementor-widget-heading\" data-id=\"6569320\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Watch keynote<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-73803eb elementor-widget elementor-widget-video\" data-id=\"73803eb\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;video_type&quot;:&quot;vimeo&quot;}\" data-widget_type=\"video.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-wrapper elementor-open-inline\">\n\t\t\t<iframe class=\"elementor-video-iframe\" allowfullscreen allow=\"clipboard-write\" title=\"vimeo Video Player\" src=\"https:\/\/player.vimeo.com\/video\/1136033063?color&amp;autopause=0&amp;loop=0&amp;muted=0&amp;title=0&amp;portrait=0&amp;byline=0&amp;h=df7601a222#t=\"><\/iframe>\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-0c640fe e-flex e-con-boxed e-con e-parent\" data-id=\"0c640fe\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-e993182 elementor-widget elementor-widget-heading\" data-id=\"e993182\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Listen to Keynote with GembaTalk Podcast<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2d3165d elementor-widget elementor-widget-html\" data-id=\"2d3165d\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t\t<div style=\"width: 100%; height: 200px; margin-bottom: 20px; border-radius: 6px; overflow: hidden;\"><iframe style=\"width: 100%; height: 200px;\" frameborder=\"no\" scrolling=\"no\" allow=\"clipboard-write\" seamless src=\"https:\/\/player.captivate.fm\/episode\/842d3b79-65e7-45d2-a21f-ea8e18216041\/\"><\/iframe><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-90205d5 e-flex e-con-boxed e-con e-parent\" data-id=\"90205d5\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-d1c21af elementor-widget elementor-widget-heading\" data-id=\"d1c21af\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Key takeaways<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-12a8b74 elementor-widget elementor-widget-text-editor\" data-id=\"12a8b74\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<h3>1. It&#8217;s Not Just About Culture &#8211; You Need Tools and Techniques Too<\/h3>\n<p>Tom challenged the notion that lean transformation is solely about creating culture, despite the fact that his own book emphasizes creating an &#8220;extraordinary lean culture.&#8221; He observed a consistent pattern he calls &#8220;lean fireworks&#8221; &#8211; organizations that start with tremendous energy and cultural enthusiasm, only to hit a plateau or brick wall after three months and give up.<\/p>\n<p>The problem? Culture alone isn&#8217;t enough. Without deep knowledge of lean tools and techniques, organizations inevitably stagnate. Tom pointed to his visit to Wrotham earlier in the year, where he witnessed a team with the broadest and deepest appreciation for lean he&#8217;d ever seen, achieved by taking time with Toyota experts to develop comprehensive technical knowledge. The lesson: you need both culture and technical expertise to sustain your lean journey.<\/p>\n<h3>2. Not Everyone Has to Be a Lean Maniac<\/h3>\n<p>The expectation that 100% of employees will become &#8220;lean maniacs&#8221; making two-second improvements every single day is not only unrealistic but harmful. Tom asked the audience how many had organizations where everyone fits this description &#8211; predictably, no hands went up.<\/p>\n<p>The reality follows a Pareto distribution: on a good day, about 20% of people will be lean maniacs who show themselves early, while 80% will be happy to work in a positive environment and contribute improvements at a sustainable pace. Even Seating Matters sets a bar of just two improvements per month for their people. Tom urged leaders to stop calling people failures for not meeting &#8220;some stupid, unrealistic target that&#8217;s unsustainable.&#8221;<\/p>\n<h3>3. Lean Happens in the Supply Chain Too<\/h3>\n<p>One of the most overlooked areas for lean improvement is the supply chain and customer interface. Tom shared a powerful example from his automotive supply chain days where he visited a supplier and discovered they were manufacturing products in batches according to purchase order quantities.<\/p>\n<p>By eliminating the batch mentality and implementing consignment stock at their factory, they saved more than half a million euros in working capital with a single improvement. He emphasized the importance of not just sitting in offices during supplier or customer visits, but going to the gemba with &#8220;big eyes and big ears&#8221; to understand their processes and how your organization interfaces with theirs. Whether it&#8217;s suppliers driving unnecessary costs or customers struggling to find your products in their goods-in area, enormous opportunities exist beyond your four walls.<\/p>\n<h3>4. Respect for People Is More Than Being Nice<\/h3>\n<p>Tom addressed what he called &#8220;one of the most misunderstood things in lean&#8221; &#8211; respect for people. Citing his friend Alex Ramirez, one of the best lean coaches in the world, he defined respect for people as four elements: dignified work, dignified pay, dignified place, and dignified treatment. If you&#8217;re missing any of them, lean won&#8217;t work.<\/p>\n<p>He spent particular time on dignified pay, sharing a story of an industrialist who built a 300-million-pound business but struggled with 40% labor turnover. When this leader noticed McDonald&#8217;s was paying \u00a312.58 per hour while his welders earned \u00a314.50 for dirty, physically difficult work, he courageously raised wages by \u00a32 per hour despite management resistance.<\/p>\n<p>The result? Labor turnover dropped to almost nothing overnight, and he called it &#8220;the biggest cost saving he ever made in his career.&#8221; The recruitment costs, onboarding time, quality defects from inexperienced workers &#8211; all disappeared. Tom noted that for every 10% of labor turnover, you lose 1% of gross margin, and urged leaders to look honestly at their pay if turnover exceeds 10%.<\/p>\n<h3>5. Deep Knowledge Requires Real Training<\/h3>\n<p>Tom pushed back against what he called the &#8220;dogmatic&#8221; DIY approach where training happens only in morning meetings. Drawing on his first ten years in automotive supply chain, he recalled spending 20 days a year in classroom training developing deep knowledge of lean tools and techniques.<\/p>\n<p>While that system lacked employee voice and cultural elements, the technical foundation was solid. He argued that the pendulum has swung too far in the opposite direction, with too much emphasis on culture and not enough on developing genuine technical expertise. Organizations need structured learning, not just daily kaizen, to build the capability required for sustainable transformation.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-ebf164a e-flex e-con-boxed e-con e-parent\" data-id=\"ebf164a\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-fd5b4d5 elementor-widget elementor-widget-heading\" data-id=\"fd5b4d5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h4 class=\"elementor-heading-title elementor-size-default\">Speaker details<\/h4>\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-9a51563 e-con-full e-flex e-con e-child\" data-id=\"9a51563\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t<div class=\"elementor-element elementor-element-cc929b8 e-con-full e-flex e-con e-child\" data-id=\"cc929b8\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-0b86d46 elementor-view-stacked elementor-shape-circle elementor-widget elementor-widget-icon\" data-id=\"0b86d46\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"icon.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-icon-wrapper\">\n\t\t\t<div class=\"elementor-icon\">\n\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-user\" viewBox=\"0 0 448 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M224 256c70.7 0 128-57.3 128-128S294.7 0 224 0 96 57.3 96 128s57.3 128 128 128zm89.6 32h-16.7c-22.2 10.2-46.9 16-72.9 16s-50.6-5.8-72.9-16h-16.7C60.2 288 0 348.2 0 422.4V464c0 26.5 21.5 48 48 48h352c26.5 0 48-21.5 48-48v-41.6c0-74.2-60.2-134.4-134.4-134.4z\"><\/path><\/svg>\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f028157 elementor-widget elementor-widget-heading\" data-id=\"f028157\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<p class=\"elementor-heading-title elementor-size-default\">Who<\/p>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2b151c4 elementor-widget elementor-widget-text-editor\" data-id=\"2b151c4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><a href=\"https:\/\/www.linkedin.com\/in\/tom-hughes-gembadocs\/\">Tom Hughes<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-fdd7ac7 e-con-full e-flex e-con e-child\" data-id=\"fdd7ac7\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-ee9696a elementor-view-stacked elementor-shape-circle elementor-widget elementor-widget-icon\" data-id=\"ee9696a\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"icon.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-icon-wrapper\">\n\t\t\t<div class=\"elementor-icon\">\n\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fas-location-arrow\" viewBox=\"0 0 512 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M444.52 3.52L28.74 195.42c-47.97 22.39-31.98 92.75 19.19 92.75h175.91v175.91c0 51.17 70.36 67.17 92.75 19.19l191.9-415.78c15.99-38.39-25.59-79.97-63.97-63.97z\"><\/path><\/svg>\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1ff456e elementor-widget elementor-widget-heading\" data-id=\"1ff456e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<p class=\"elementor-heading-title elementor-size-default\">from<\/p>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-76426d2 elementor-widget__width-initial elementor-widget elementor-widget-text-editor\" data-id=\"76426d2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><a href=\"https:\/\/gembadocs.com\/\">GembaDocs<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-7a9d9fe e-con-full e-flex e-con e-child\" data-id=\"7a9d9fe\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-d4a5867 elementor-view-stacked elementor-shape-circle elementor-widget elementor-widget-icon\" data-id=\"d4a5867\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"icon.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-icon-wrapper\">\n\t\t\t<div class=\"elementor-icon\">\n\t\t\t<svg aria-hidden=\"true\" class=\"e-font-icon-svg e-fab-youtube\" viewBox=\"0 0 576 512\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"><path d=\"M549.655 124.083c-6.281-23.65-24.787-42.276-48.284-48.597C458.781 64 288 64 288 64S117.22 64 74.629 75.486c-23.497 6.322-42.003 24.947-48.284 48.597-11.412 42.867-11.412 132.305-11.412 132.305s0 89.438 11.412 132.305c6.281 23.65 24.787 41.5 48.284 47.821C117.22 448 288 448 288 448s170.78 0 213.371-11.486c23.497-6.321 42.003-24.171 48.284-47.821 11.412-42.867 11.412-132.305 11.412-132.305s0-89.438-11.412-132.305zm-317.51 213.508V175.185l142.739 81.205-142.739 81.201z\"><\/path><\/svg>\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-206194c elementor-widget elementor-widget-heading\" data-id=\"206194c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<p class=\"elementor-heading-title elementor-size-default\">YouTube<\/p>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d4e1cf1 elementor-widget elementor-widget-text-editor\" data-id=\"d4e1cf1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><a href=\"https:\/\/www.youtube.com\/@GembaDocs\">GembaDocs<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-5f98b28 e-flex e-con-boxed e-con e-parent\" data-id=\"5f98b28\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-8b76823 e-con-full e-flex e-con e-child\" data-id=\"8b76823\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t<div class=\"elementor-element elementor-element-560f842 e-con-full e-flex e-con e-child\" data-id=\"560f842\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-ce02251 elementor-widget elementor-widget-heading\" data-id=\"ce02251\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t\t<h4 class=\"elementor-heading-title elementor-size-default\">Gemba Summit News &amp; Updates<\/h4>\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-05f8f1f elementor-widget elementor-widget-video\" data-id=\"05f8f1f\" data-element_type=\"widget\" data-e-type=\"widget\" data-settings=\"{&quot;video_type&quot;:&quot;vimeo&quot;}\" data-widget_type=\"video.default\">\n\t\t\t\t\t\t\t<div class=\"elementor-wrapper elementor-open-inline\">\n\t\t\t<iframe class=\"elementor-video-iframe\" allowfullscreen allow=\"clipboard-write\" title=\"vimeo Video Player\" src=\"https:\/\/player.vimeo.com\/video\/1138927500?color&amp;autopause=0&amp;loop=0&amp;muted=0&amp;title=0&amp;portrait=0&amp;byline=0&amp;h=408d148cac#t=\"><\/iframe>\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7dc30f9 elementor-widget elementor-widget-text-editor\" data-id=\"7dc30f9\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<p><strong>Want to join the lean revolution?<\/strong><\/p>\n<p>Then sign up for Gemba Summit newsletter, and you&#8217;ll be the first to know when, where and how to be part of the movement.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-bad9624 e-con-full e-flex e-con e-child\" data-id=\"bad9624\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-c0abebd elementor-widget elementor-widget-hubspot-form\" 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