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Podcast· 8 episodes

The LeanSuite Podcast by Angad Singh

Lean manufacturing without the theory. Short episodes on what actually happens on a shop floor after the workshop ends: where rollouts stall, why fixes don't stick, and where to start. Each one comes with two free resources from this site you can use the same day.

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Cover art for The LeanSuite Podcast by Angad Singh

Latest episodeEpisode 8 · October 26, 2026 · 8 min

Encore: Did We Put A Band Aid, Or Did We Actually Kill It?

An encore of one of the most-listened episodes of the show. Angad talks about what happens when problems get logged, bounced around and closed without ever getting to the root cause. He covers capturing every problem in one place, tags that get reassigned instead of resolved, why a one point lesson expires after 60 days, and what it takes to make a fix stick.

Listen · 8 min

Show notes and quotes

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Free on this site, picked for this episode.

What the episodes cover

Kaizen and continuous improvement4 of 8 episodes
Lean leadership and employee engagement4 of 8 episodes
Lean manufacturing fundamentals2 of 8 episodes
Root cause analysis and problem solving2 of 8 episodes
Standard work, SOPs and training2 of 8 episodes
Quality management1 of 8 episodes

Each episode links the topics it touches, shown as chips on its card. The bars count them across all 8 episodes, so the longest bars are the problems the show comes back to most.

Earlier episodes

Episode 7 · October 21, 2026 · 5 min
A lot of these engagements are one time engagements
Angad talks about why consulting engagements end and the results fade, and why people need to be doing it themselves to sustain it. He covers how a consultant can set up a client's kaizens, audits and training in a platform during the engagement and stay connected afterwards.
Listen · 5 min
Use these today
- Free template · PDF and ExcelEmployee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Free training deck · PowerPointLayered process audit (LPA) training presentationWhat a layered process audit is, the layers, how to write and ask good questions, handle a no and read the results, in 19 slides.
- Lean leadership and employee engagement
- Kaizen and continuous improvement
Episode page
Episode 6 · October 10, 2026 · 11 min
It Just Takes Forever for Manufacturing
Angad on why most factories are still behind on anything digital, and why the answer is usually "we're able to do it on Excel." He walks through what he sees in discovery, why bigger companies take it on faster than small shops, and the three things a project needs to actually happen. He also lays out where a plant should start — visibility into daily in and out — and the employee count where this starts to pay for itself.
Listen · 11 min
Use these today
- Free template · PDF and ExcelDigital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Free template · PDF and ExcelEmployee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Lean leadership and employee engagement
- Lean manufacturing fundamentals
Episode page
Episode 5 · October 7, 2026 · 10 min
Corporate gives you 90 million and you find the other 10
Angad walks through how plants get handed a year over year savings target, how the budget gets built ground up and then cut, and why the target should come from the bottom up instead of top down. He goes through the different types of savings — hard savings, virtual savings, cost avoidance — and how project work gets tracked month over month. He also covers the two questions he asks before building an ROI: what is your savings target for the year, and have you been meeting it.
Listen · 10 min
Use these today
- Free template · PDF and ExcelCost savings trackerA savings log with hard and soft savings, payback and Finance's sign-off, plus a glide path against the year's target.
- Free calculatorKaizen savings calculatorYearly savings, payback in months and first-year ROI of an improvement, from time saved, scrap avoided and its costs.
- Kaizen and continuous improvement
- Quality management
Episode page
Episode 4 · October 5, 2026 · 11 min
If the data isn't even there, there aren't any action items
Angad talks about what he's seen on plant floors where lean work lives on spreadsheets, paper and whiteboards with tags pinned by hand. He covers why paper means there's no data, and no data means no action items to track, why homegrown fixes break down after a few years, and where he tells people to start instead. He ends with the question he asks to see if any of it is worth it: how much admin work is going into managing all this today.
Listen · 11 min
Use these today
- Free template · PDF and ExcelRolling action item list (RAIL) templateA single running list of actions kept from meeting to meeting, with a weekly review sheet and age counts.
- Method guideRolling action item list (RAIL)What a rolling action item list (RAIL) is, why sources disagree on whether the L is list or log, the columns that matter, how to run the weekly review, ageing and closing rules, a worked example with the sums, and how a RAIL differs from meeting minutes, a tier board, a CAPA log and a kaizen list.
- Lean leadership and employee engagement
- Lean manufacturing fundamentals
Episode page
Episode 3 · September 30, 2026 · 7 min
Pick One Pilot Area, One Pain Point, And Start There
“What we usually say is, pick one pilot area and pick one very specific pain point and start there, and then grow your team and do the train the trainer and expand it throughout the facility.”
Angad Singh, in the episode
Listen · 7 min
Use these today
- Free template · PDF and ExcelIdea suggestion formThe episode says start with suggestions and kaizen only. This is the form and the idea log.
- Free template · PDF and Excel1-1-90 method worksheetScore your areas, write the one pain point with a number, then plan days 30, 60 and 90 and what comes after.
- Kaizen and continuous improvement
- Lean leadership and employee engagement
Episode page
Episode 2 · September 28, 2026 · 8 min
Did We Put A Band Aid, Or Did We Actually Kill It?
“Did we put just a band aid at that time because we needed volume, or is it that we actually solved the problem so it will never happen again?”
Angad Singh, in the episode
Listen · 8 min
Use these today
- Free template · PDF and ExcelTPM tag logEvery tag in one list with who fixes it and days open, so you can see which ones never close.
- Free template · PDF, Excel and WordOne point lesson (OPL) templateOne point on one page. The episode's rule: after 60 days it moves into standard work.
- Root cause analysis and problem solving
- Standard work, SOPs and training
Episode page
Episode 1 · September 26, 2026 · 8 min
Don't Work on Line Number Two, Work on Line Number One
“So even though they're both down for 10 minutes, forget about line two right now, work on line one.”
Angad Singh, in the episode
Listen · 8 min
Use these today
- Free calculatorDowntime cost calculatorTwo lines down for 10 minutes can cost very different amounts. Put a number on each one.
- Free template · PDF and ExcelCost deployment matrixCausal and resultant losses turned into money, so the loss tree ranks by cost, not minutes.
- TPM and maintenance
- Kaizen and continuous improvement
Episode page

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