Ryan Tierney (Lean Made Simple) sits down with producer Alastair Luke (Attention X) shares the brutally honest truth about what’s really happening six months into the Lean transformation at Sperrin Metal.Customers haven’t seen the benefits yet.Lead times have got worse.The factory is still operationally chaotic.And it’s been the most difficult thing he’s ever done.In this open and unfiltered conversation, Ryan explains what it actually looks like when you try to transform a 63-year-old manufacturing company.🟢 What it feels like to take responsibility for 100 people overnight🟢 Why Lean sometimes makes things worse before they get better🟢 The decision to reduce 48 types of sheet metal down to 9🟢 Why they’re questioning absolutely everything🟢 How defects are silently destroying profit🟢 What “your wealth is in your waste” really meansThis isn’t a highlight reel.This is what Lean looks like mid-transformation.If you think Lean is quick, easy or automatic, this episode will challenge that belief.⸻➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Find out more about Sperrin Metal at www.sperrin-metal.com

Only a few weeks into taking over Sperrin Metal, Ryan Tierney is revealing the first real progress inside one of the most chaotic factories he has ever stepped into in this podcast recorded live at the Gemba Summit.This is the story of what he found on day one, what has changed already, and how Lean Thinking is beginning to transform a 63-year-old manufacturing company from the inside out.In this first-phase update, Ryan shares the breakthroughs, the challenges, and the mindset shifts that accelerated improvement faster than anyone expected.From disorganised processes to early wins, from scattered workflows to the foundations of daily improvement, this episode shows the real-world reality of starting Lean in a place that desperately needed it.You’ll see:🟢 What Ryan discovered when he first walked into Sperrin Metal🟢 How the team responded to Lean from day one🟢 The first systems put in place to stabilise workflow🟢 Why culture and structure came before tools🟢 How the Lean Dream Team unlocked early momentum🟢 The mindset shifts that allowed progress in weeks, not months🟢 Why chaos is the best starting point for transformationIf you’re a factory manager, operations leader, or Lean practitioner, this update gives you a rare inside look at what Lean actually looks like in the early days — messy, fast, energising, and full of opportunity.Watch now and see how Lean Made Simple is beginning to reshape Sperrin Metal from the ground up.⸻🔗 Next steps➡️ View the keynotes from the Gemba Summit at the ⁨@GembaDocs⁩ YouTube channel➡️ Order the book Lean Made Simple – 12 Proven Steps for Creating a Vibrant Lean Culture: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour➡️ Join the Lean Made Simple community: https://www.leanmadesimple.com/community⸻✅ KeywordsLean manufacturing Lean transformation continuous improvement factory update factory tour Kaizen 5S workflow improvement operational excellence manufacturing systems Lean culture Lean leadership Sperrin Metal transformation Lean Made Simple Gemba Summit production efficiency#LeanManufacturing #ContinuousImprovement #LeanTransformation #SperrinMetal #LeanMadeSimple #OperationalExcellence #Kaizen #ManufacturingTransformation #LeanLeadership #LeanCulture

Ryan Tierney (Lean Made Simple) delves deep into Ireland's BIGGEST ever Lean summit, Gemba Summit at Titanic Belfast, Northern Ireland on 20th-21st October 2025.Find out more about Gemba Summit and:- Whit can be your next lean TURNING POINT- Why people are travelling from all over the world to EXPERIENCE lean- HOW you can join some of the world top lean leaders➡️ Book your GEMBA SUMMIT tickets today: https://gembasummit.com➡️ Order the book, LEAN MADE SIMPLE: 12 PROVEN STEPS FOR CREATING A VIBRANT LEAN CULTURE: https://www.leanmadesimple.com/store➡️ Book a Lean Made Simple tour: https://www.leanmadesimple.com/book-a-tour➡️ Subscribe to the Lean Made Simple podcast.Apple Podcasts: https://podcasts.apple.com/gb/podcast/lean-made-simple-transform-your-business-life-one-step/id1693831884Spotify: https://open.spotify.com/show/6bUJ0QwamrZjjvfpUkQrCq