The Rest is Lean
The Rest is Lean Channel is a light-hearted and educational look at how to make businesses better through Lean Manufacturing and Operational Excellence. Suited for all levels of understanding and from any industry or geographical region.John, Alan & Russell are time-served lean professionals with over 30 years each in this field. Leading and coaching some of the best businesses from SMEs to multi-nationals.Trained by some of the highest calibre Japanese masters from Toyota(one step from Ohno himself), Honda and Nissan , we want to share our experiences with you, allowing some of these 'pearls of wisdom' to help make your b...
Recruiting Lean Queens - LinkedIn Lunacy, Zoom Chaos & Gemba Games
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Problem solving the challenge of finding Lean strength and depth in your organisation. What traits should we be looking for and what should set the alarm bells? Does LinkedIn and Zoom help or hinder in making the right decision?
These are some of the questions we take from our subscribers and followers. In this episode we try to tackle these and ask a few more:
Develop from within or recruit?
What balance is to be made of theory v application?
People centric or shiny new machines
...
Lean v Elon Musk, Smugglers and "The Idiot Index"
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Elon Musk and Drug Smugglers. Can we learn from those we may not like? Are our biases meaning that we are missing a good opportunity to learn?
The new series of The Rest is Lean Podcast gets underway, full of interesting discussion and plenty of laughs
Following on from Alan's venting, the Team discuss how lean learning can come from those who are not necessarily the most well-liked of people
5S, 6S or 7S? 7 or 8 Wastes? Find out what boils our p!$$
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Do you really know the real well-meant intent of the Lean Tools / Techniques of 5S and 7 Wastes? Maybe you've heard 6S (or even 7S) and 8 Wastes for example and then wondered why? If so, this is the podcast episode for you!
S5 P1 The new series of The Rest is Lean Podcast gets underway, full of interesting discussion and plenty of laughs
This episode provides Alan with some opportunity to vent his frustrations on recent social media posts he's seen regarding topics such as 5S Waste Elimination...
Which Gemba would you like to go to? Lean Leadership & Analogies in Premier League Football
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Can Lean tools & techniques be applied successfully in all walks of life? Which Gemba would you like to visit to develop your knowledge and experience? From design offices to premier league football, Team TRIL discuss and debate if lean thinking is transferrable, and if so, what analogies can we draw from typical lean manufacturing?
S4 P12 Our final podcast of this series is full of interesting discussion and plenty of laughs
As well as Lean Leadership in elite sports such as football and rugby, find out how John...
The Rest is Lean Podcast LIVE Edition at Subcon 2026 aka Why does lean fail & how to avoid it
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Suffering with long lead times, poor productivity, quality, or delivery performance? Struggling to make your improvement efforts stick?Â
Learn from those with over nearly 30 years experience in the field. Japanese trained from Toyota & Honda
#TheRestIsLean goes live with our annual pilgrimage to the NEC for #SUBCON 2026. The second of 2 episodes recorded at the 2-day event which showcases some of the best products and companies that support global manufacturing
This episode involves our live interactive podcast event on the topic of "Why Lean Fails and How to A...
The TRIL Leadership Interview Series Part 2 - Mark Hemming
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The Rest is Lean (#TRIL) Leadership Series of Podcasts brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership
Each episode dives into the principles, challenges, and successes that shape modern organisations—told by those who live them every day
This episode welcomes Mark Hemming. Mark is a transformational business leader who has led major operations at Amazon, Eurocell, and HelloFresh, delivering large-scale growth, innovation and operational excellence. Having managed businesses of significant scale across multiple countries, he now advises organisations th...
The TRIL Leadership Interview Series Part 1 - Mark Hemming
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The Rest is Lean (#TRIL) Leadership Series of Podcasts brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership
Each episode dives into the principles, challenges, and successes that shape modern organisations—told by those who live them every day
This episode welcomes Mark Hemming. Mark is a transformational business leader who has led major operations at Amazon, Eurocell, and HelloFresh, delivering large-scale growth, innovation and operational excellence. Having managed businesses of significant scale across multiple countries, he now advises organisations th...
Our Visit to SubCon 2026 aka The Take That Man
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Global Manufacturing Expertise & The take that Man. Our annual pilgrimage to the NEC for SUBCON 2026. One of 2 episodes recorded at the 2-day show which showcases some of the best products and companies that support global manufacturing
This episode involves a whistle-stop tour of both Subcon2026 and SmartManufacturingWeek where TeamTRIL meet some fantastic company owners and their employees, along with some fellow panel members including:
Sophie Hall - Warren Services
Ian Joliffe - SMMT (Society Motor Manufacturers & Traders) Industry Forum
Taye Reid - The Levyne Group
...
Questions to ask to get a feel for a business aka What problem are you trying to solve?
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Back to our usual episodes and this one will really help you really get under the skin of a company in a relatively short space of time. So if you're new to a business, or a lean change agent then this episode is for you!
Russell shares his recent trip to the Northern Ireland Lean Cluster including some fantastic companies embracing the '2 Second Lean Movement'
John shares his problem solving exploits on his decking (or not!)
Team #TRIL also get to grips with those...
The TRIL Leadership Interview Series - Delphine Fillot
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The Rest is Lean (#TRIL) Leadership Series of Podcasts brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership
Each episode dives into the principles, challenges, and successes that shape modern organisations—told by those who live them every day
This episode welcomes Delphine Fillot, Group SVP Quality & Customer Excellence at Forvia
Forvia is a global automotive component manufacturer created by combining the expertise of 2 other automotive manufacturing powerhouses, Faurecia and HELLA
Delphine's experience as a...
Sustaining Lean Transformation aka How Long Do You Persevere?
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Engaging people and gaining 'Buy-in' from employees. That's the main topic of this episode of The Rest Is Lean Podcast
Join John, Russell & Alan for our usual 30minute ramble as we discuss our Lean experiences. Discussions include:
The TRIL Leadership Interview Series - Ian Mountain
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The Rest is Lean (#TRIL) Leadership Series of Podcasts brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership
Each episode dives into the principles, challenges, and successes that shape modern organisations—told by those who live them every day
This episode welcomes Ian Mountain, Managing Director of Leafield Marine based in Wiltshire
Leafield Marine is the World leader in the design, development and manufacture of valves and inflation systems for a wide range of inflatable structures in...
Does removing variation inhibit innovation? aka The Normalisation of Deviation.
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This episode sees the #TRIL Team ramble and rummage through how lean tools and techniques, flow, and human behaviour are involved/applied to the experience of driving vehicles
Russell talks about his recent speeding exploits and how his A3 summary helped him improve his driving
John shares his Honda view on the Toyota approach to standards and 5S. Alan discusses flow and a recent post by Cambridge Mathematics Professor, Hannah Fry, on the topic of "Ghost Jams".
From 5S to Standard Work to Visual Management...
Thank you for Stopping the Line aka John's 'Cuddly' Trip to Toyota Deeside
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The #TRIL Team ramble through the 2nd podcast of series 4 where the trio of John, Russell and Alan share their recent exploits and experiences
The guys talk about their recent visit to Leafield Marine where MD (and good friend of the team) Ian Mountain, took the time out to walk us around his factory and even allowed us to record a future leadership episode with him! (Watch this space)
John also shares a fascinating visit to Toyota Deeside Engine Facility where he joined a number of construction...
Lean Browsers & Ugly Babies aka David's Sandwich
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Our very own Lean Leaders of Russell, John and Alan take to the floor once again in their 4th series of The Rest is Lean Podcast
In this episode, Team #TRIL kick off the series with a rather detailed email from one of their long time followers. This develops into the usual rambling on multiple experiences of providing clients with feedback on how their businesses are running and where to focus your improvement efforts. It's not always as shiny and bright as you may think!
What's different...
The TRIL Leadership Interview Series - Astrid Mozes
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In this episode, Alan welcomes his friend and work colleague from days gone by, Astrid Mozes. With decades of leadership experience within global manufacturing organisations such as Eaton and Danfoss, having held positions as CTO, VP, SVP and President, Astrid is now Chair of the Swedish-American Chamber of Commerce in Minnesota
As she takes us through her background and passion for manufacturing and technology, Astrid shares why she enjoys her work, the people she has learned from, and how she maintains her energy for moving businesses forward
From industry...
How Lean Helps in Real Life aka The Puppet Show Looks Different but the Strings are the Same!
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Another down to earth episode of #TheRestIsLean Podcast with Team TRIL (Russell, John and Alan).
In this episode, find out:
- How John's 'Soul Searching' went
- The end result of Russell's recent training in Alchemy!
- Tips on how to get the best out of your plant tours and visits
- What examples the trio can share in terms of how lean principles have helped them personally, outside of the workplace. (some fascinating personal examples of 5S, Visual Management, TPM and Problem Solving which...
Who's your Phone-A-Friend Al? aka The Problem, The Difficulty!
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The 'Leaders of Lean' in the form of John, Russell, and Alan embark on another ramble of lean proportions
In this jam-packed episode, Team #TRIL discuss topics such as:
- Russell's start-up escapades
- John's Coat of Arms and Alchemy links
- Alan's appearance in the 'Hot Seat' of a well known TV show #wwtbamÂ
- Artificial Intelligence; is one better than the others? What should we be wary of?
- Practical Problem Solving; real life examples and the importance of effective problem definition
The TRIL Leadership Interview Series - Rob Marchant
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The Rest is Lean (#TRIL) Podcast brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership
Each episode dives into the principles, challenges, and successes that shape modern organisations—told by those who live them every dayÂ
In this episode, Alan welcomes Rob Marchant, Chairman & Founder of The MarchantCain Group. (www.marchantcain.com)
Specialist designers, makers and builders of complex mechatronic components that enhance the aesthetic form and function of our customers’ vehicles in a multitude of industries.
F...
I'll Stop When You Squeak! aka What Happens if We Don't Improve?
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Another exciting episode from the guys at TRIL
In addition to the usual banter from the three lean musketeers, and the usual 'Quote of the Week' segment, find out why:
- Russell enjoyed his books and recent Taphouse visits
- John is getting so excited about his electric tricycle
- Alan is talking about his exploits in Silicon Spa!
They also take some of subscriber questions and offer their thoughts.
If you're enjoying what we do and want to keep up to speed...
Leadership, Listening and Gemba aka Looking Through a Different Lens
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The #TRIL Team get together once again to share their experiences through their decades in Lean Transformation, Leadership and Continuous Improvement endeavours.
In this episode learn about:
- Traits of a good leader such as active listening
- The Importance of Gemba
- Football Mascots
- Spying in changing rooms (not!)
- Clarity & Conciseness
- Why are John's jacket pockets so big?!
If you're enjoying what we do and want to keep up to speed with the latest episodes, then don't forget...
The Tact of Takt II aka You Can't Be a Little Bit Pregnant!
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A continuation from our previous Tact is Takt episode, due to the deluge of questions asked by our subscribers.Â
Options to deal with variations in your Takt calculation, visualising the opportunity for further improvement, skills, flexibility, 8 Wastes, and the impact of WIP are all touched upon in this jam-packed episode.
If you're enjoying what we do and want to keep up to speed with the latest episodes, then don't forget to subscribe, click the bell notification icon, and share with anyone else you know who may be interested.
The Tact of Takt aka A Trip to Japan
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The #TRIL Team are back with another episode sharing their latest exploits and experiences, revolving around lean leadership, continuous improvement and OpEx.
In this episode Russ gives us an insight into his recent trip to Japan, and John rambles on around the adventures of the great John Adair.Â
We also discuss the question ' What is the smallest hill you would die on?' which conjures up some interesting topics such as OEE and Takt Time.
If you're enjoying what we do and want to keep up t...
The TRIL Leadership Interview Series - Glyn Holman
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The Rest is Lean (#TRIL) Podcast brings you powerful conversations with professionals from across the globe, sharing real-world experiences in lean manufacturing and leadership.Â
Each episode dives into the principles, challenges, and successes that shape modern organizations—told by those who live them every day. From industry veterans to innovative thinkers, our guests reveal practical insights, cultural shifts, and leadership strategies that drive transformation.Â
Whether you’re a business leader, lean practitioner, or simply curious about what makes organizations thrive, #TRIL delivers stories and lessons that inspire action. Tune i...
PDCA or CAPDo aka In-SPIRE-ing Lean
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Another episode for Team #tril to get their teeth into and they get underway with some subsciber questions, one of which with a 'divine' theme which leads them to exploring the statement that Lean can be applied anywhere and everywhere.
Alan brings a recent experience of 5S/6S and even 7S, and asks if this is necessary or just over-complication.Â
Find out also what is meant by the phrase "Join those that know how to join the canoe."
If you're enjoying what we do and w...
Lean You Wouldn't Do? aka Red Flags & Frogs in Wells
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John returns to the fold from his hiatus.
Team #tril revisit a previous episode with some real world examples of where potentially doing too much lean has had some 'interesting' consequences!
They also challenge their values and beliefs when it comes work. Find out what work the boys have declined and why, plus what are the red flags that make them think again!
There's also our Saying of the week and what is meant by 'A Frog in A Well', plus also find out why John is...
Voice of the Customer aka The 'Pull' of Learning
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The Dynamic Duo of Russell & Alan bring in Series 3 with a bang!
With John missing (don't worry he'll be back!) the guys get stuck in to topics and comments from our audience.
In this episode we focus on Voice of the Customer and the 'pull' this can provide businesses to learn about what adds value for customers. Knowing the difference between 'needs' and 'wants' is vital.
We also manage to cram in assessment pitfalls, the view of Quality in an organisation's structure, and a 'Karakuri' museum in...
Season 2 Finale aka Tool or not to Tool, That is the Question
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As Team #TRIL bring this season to a close, they try to address some of the ever expanding questions the pod is receiving from its ever increasing subscriber base.
"Which one of the improvement tools would you suggest to train a newbie in first?"
"What improvement literature would you refer to someone interested in lean?"
As ever, you maybe surprised by their answers, but you won't be surprised that they do not agree!
Finally our Quote of the Week segment helps us close off a...
Too Much Lean, Is it possible? aka Tesla and Toyota Insights
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This episode looks at a question many of our subscribers are asking:
Can you do too much lean?
Team #TRIL try their best to share their views on this very interesting topic by covering certain points such as:
- "Rationing" Kaizen
- Driving the right behaviours for Lean.
- Dangers associated with building a CI Culture
- Managing Opportunity
- Insights into Tesla and Toyota's approach
In addition we cover our "Quote of the Week"
If you're enjoying what...
World Class Team Leader Training Ideas aka Is This Legal???
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Continuing on from our previous episode on world class team leader competencies, the #TRIL Team talk about their experiences on courses they've led or experienced by others, to help create these competencies and instil in future team leaders.
You'll find some of those experiences quite extreme to say the least!
They also cover:
- Bootcamps
- Scenario Learning
- Sheep Dipping
- Knowledge v Skill
- The importance of planning and preparation to your training strategy
If you're enjoying what...
World Class Team Leader Competencies aka Going Global
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This episode is going places! Russell shares with the team the reach that the podcast is extending to. You'll be surprised (but not as much as we were!)
Team #TRIL delve into the world of the team leader to understand the competencies that make truly world class TLs, as well as discuss some of the pitfalls companies should be aware of when selecting them. Is there a secret sauce?
Topics include:
Visual Management, Gemba and Escalation aka 'The Autonomic System'
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Following on from the last episode on SQCDP, the #tril Team use this as an opportunity to answer some of the great questions we've had from our listeners.
Topics include:Â
- Visual Management in general
- The 1-3-10 rule & 1-3-3 rule for visual management boards
- Rules of escalation
- Scenario based training
- The benefits of going to Gemba for a leader and how to make time if you're struggling
- What is an Autonomic System?
Le...
Measuring SQCDP and ensuring value over cost aka 'The measures of unintended consequence'
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Following the aftermath of #subcon2025, Team #TRIL discuss the dangers of measuring the wrong things in your business. and how to ensure you have balance to drive the right behaviours and enable your business to thrive!
Other topics include:Â
- Russell interviewing the wife (will ours be next!) and the sacrifices we sometimes have to make.Â
- Being a pigeon and Floor Space Utilisation.
- The Parenting Problem
- John and his measures of unintended consequence.
- Alan and the importance of value rather th...
Keeping it simple is the key to sustainable lean transformation aka 'Goat or Car'
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Sustainability and keeping it simple!!Â
Continuing our conversations around lean transformation and sustaining it in your business, John, Russell & Alan (Team#tril) have finally recovered from their trip to #subcon2025.
As well as our regular 'Japanese Word' slot the guys continue with their tips and thoughts which can simply be put into practice to aid you on your improvement journey.
John brings 'The FOG Index' and 'The Stirling Engine' to the table (which blows Alan's mind!!!)
Russell discusses the power of 'Fixed Point Photography' t...
#subcon2025 Special Edition. Podcast live at the NEC 'Why lean sustainability can fail'
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For the first time ever, The Rest is Lean Podcast goes on the road! This time to Subcon2025 at the NEC in Birmingham UK. #subcon2025 Â
The #trilteam enjoy a jam-packed 2 days at the event, taking in some fantastic examples of manufacturing innovation from companies all over the globe.Â
We continued our theme on sustainability of lean transformation projects. Offering insights into what has worked (and not worked) for us during our careers, plus some great questions from our audience both during and after the session. Even some of ou...
Barriers to sustainable Lean. Visible support & need 4 lean aka 'When no problem is a problem'
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Sustainability is the name of the game. Lean Transformations and how to make them stick!
In preparation for our pending visit to #subcon2025, Team #tril discuss some of the key attributes that make a lean transformation a successful lean transformation.
Russell shares his recent visit to Bentley Motors and shares a very interesting 'mystery' item.
Last but certainly not...
Useful Gadgets & Team Dynamics for #lean professionals #nlp aka 'Man Down Man Down!'
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Oh no what are we to do? Where is Russell?
Both John and Alan hold the fort this time around as Russ takes a well deserved break.
As well as catching up on recent events, the #TRILTeam (Lite!) get onto the topics of Team Dynamics and Activity 'Gadgets'.
How important is team makeup and what sources are out there which can help us establish the right balance?
What gadgets come in useful when carrying out our lean activities and how has it changed through the years?
<...
Quality, Cost & Delivery #qcd The essential KPI's for every lean team brief? aka Q&A Session
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If you thought the last episode was a good one then you're in for a real treat with this!
Our first Q&A Podcast of the new series sees #TeamTRIL go through a raft of questions posed by our subscribers.
Our Japanese word of the week segment gets another look in, plus the usual trolling of Russell!
There's even an opportunity to learn how to see us live later in the year as we take the podcast 'on tour' to the #subcon2025 event at the NEC Birmingham...
The 4 types of problem solving skill. Is return to standard Kaizen? aka New season Rambling
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Series 2 gets underway with a belter!
#TeamTRIL share some of their problem solving experiences (good & bad).
There's some good old-fashioned 'kimono opening' by the guys along with Russ' Japanese Word of the Week and his "Ambush Question".Â
There will definitely be some 'Restless Reflection' in this section of the Pod, including:
Is getting back to standard actually Kaizen?
What are the 4 types of Problem solving skill?
Can anyone decipher Mr Watkins' scribble? (Apparently its gold to anyone who can!)
Rachel Reeves faces UK manufacturing questions aka 'Look after our SMEs & Apprentices!'
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As Series 1 comes to a close #TeamTRIL discuss Russ' recent visit to the Make UK Conference in London. As well as playing 'Word Bingo' and fine craft beers (don't ask!!), some of the key questions, posed to Chancellor Rachel Reeves, are shared, providing an opportunity for the guys to offer their thoughts on those very important topics
Our Japanese word of the week makes another appearance
Remember that if you want to get involved with your questions, comments, and tips of your own then don't forget to email the...
