COMING 2026

How Lean Leaders Engineer Sustainable Performance

Most lean programs deliver a strong turnaround. Few become lasting transformations. This book contains the framework that closes that gap — built on a real manufacturing floor, maintained for 13 years, and now documented in full for the first time.

"Most lean implementations end up being great turnarounds but not real transformations. To bring about real, lasting lean transformation, we need to ensure the leaders driving the change have the capacity to lead it and absorb the turbulence that gets in the way."

Not wellness advice. Not time management hacks. Not executive coaching. This is applying the exact Toyota Production System frameworks you already trust on the shop floor to how you manage your own 168 hours per week.

Personal Value Stream Mapping

Map where your 168 hours actually go vs. where they should go. Identify value-add vs. waste. Quantify capacity utilization.

Task Standard Work

Document repeatable tasks once, execute without cognitive load. Reduce decision fatigue on routine work.

Leader Standard Work

Color-coded weekly schedule protecting strategic time, 1:1s, and thinking capacity. Visual management for your week.

Buffer Capacity Engineering

Size protective capacity using demand variability and complexity. Prevent buffer erosion ("just one more thing").

Leadership Performance Tracking

Measure availability loss (interruptions), performance loss (decision fatigue), quality loss (rework). Track improvement over time.

Preventive Maintenance Protocol

Measure availability loss (interruptions), performance loss (decision fatigue), quality loss (rework). Track improvement over time.

These aren't new frameworks. You already use them on production lines. This book shows you how to apply them to yourself.

Specifically: VP Operations, VP Engineering, COOs, and Directors at manufacturing and growth-stage technology companies (100-300 employees) who have 20+ years in operations, are TSSC or Lean Six Sigma trained, and have built world-class production capacity systems.

You'll recognize yourself if:

✓ You know the Muri→Mura→Muda sequence by heart

✓ You've led kaizen events and speak capacity utilization fluently

✓ You systematically engineer capacity for production lines using TPS principles

✓ But you run your own leadership capacity at 150% with no buffer, no Standard Work, no preventive maintenance

✓ Your highest-value work (coaching, strategic thinking, system design) disappears under firefighting

✓ You're facing personal capacity failure, team burnout cascade, and strategic initiatives delayed

This is not for: General leadership. HR professionals. Executive coaches. Wellness consultants. This is operations-specific, TPS-validated, for people who speak throughput and takt time.

Operations language exclusively. Every framework uses Lean/TPS terminology. No wellness jargon. No self-care. No work-life balance. This is capacity engineering.

Measurable, systematic approach. You'll baseline your leadership capacity utilization, implement frameworks, track variance, and run PDCA cycles. Like you do for production.

Written by an operations leader. 20+ years in manufacturing operations, former Director of Manufacturing Operations, 59 kaizen events led. Not a consultant observing from outside, a practitioner who lived this.

Answers the unanswered questions. The 10 critical questions about leadership capacity engineering that don't have satisfactory answers in existing Lean literature. This book addresses each one.

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