The Practical Improvement Series: Episode 3: Deeper Dive Into The Lean Process

We continue our series collaboration between Adriana Torres of The Process Reinvention and me. This time, I asked Adriana a question.
Melissa’s question to Adriana: Can you dig deeper into Lean and talk about the most important aspect of the Process and how does that help anyone implementing it?
I like that, diving deeper into the process, because once we start doing this and understanding more of what really is happening within the process, we can start to become the owners of the process instead of the ones on the receiving side of a process that is not necessarily supporting us in efficient and effective ways.
As I like to say, “There is more to the process than meets the eye.”
I know that I sound like The Transformers, but it is absolutely the case!
That quote is powerful because it points to a truth most organizations miss:
The process you see is rarely the process that’s actually running.
There are hidden forces working against you, your team, and your customer. Let’s unveil them!
Your processes have the following features,
Visible Process
→
Hidden System
(steps) (forces shaping the steps)
1️⃣ The “Shadow Process” (Workarounds & Shortcuts)
What it looks like:
- “We don’t really follow that step… we just…”
- Extra emails, side conversations, manual fixes
- Tribal knowledge instead of standard work
What’s happening:
- The
real
process is different from the documented one
Lean insight:
- Workarounds = signals of broken flow
Risk:
- Inconsistency
- Training gaps
- Hidden waste
2️⃣ Misaligned Incentives (Metrics Driving the Wrong Behavior)
What it looks like:
- Speed prioritized over quality
- Output over Customer Value
- “Hitting the numbers” at any cost
What’s happening:
- The system rewards behavior that undermines the process
Lean insight:
- People don’t resist systems — they respond to them
Risk:
- Local optimization, global failure
3️⃣ Cognitive Biases (Invisible Decision Errors)
What it looks like:
- “We’ve always done it this way”
- Overconfidence in poor estimates
- Ignoring data that contradicts beliefs
What’s happening:
- Human thinking shortcuts distort reality
Lean connection:
- Bias affects root cause analysis and decision-making
Risk:
- Solving the wrong problem repeatedly
4️⃣ Unclear Ownership (Diffused Responsibility)
What it looks like:
- “That’s not my job”
- Delays at handoffs
- Decisions bouncing between people
What’s happening:
- The process lacks clear accountability
Lean insight:
- Flow breaks where ownership is unclear
Risk:
- Bottlenecks and frustration
5️⃣ Emotional Undercurrents (Fear, Blame, Avoidance)
What it looks like:
- Problems hidden instead of raised
- Silence in meetings
- Blame when things go wrong
What’s happening:
- The culture discourages transparency
Lean principle:
- Respect for people = psychological safety
Risk:
- Problems grow in the dark
If you detect that many of these are happening systematically in your organization, more likely there is plenty of waste going around that remains
invisible.
Next time, we will go deeper into what can be done to counter these wasteful issues hidden within the process.
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