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Artificial Intelligence is everywhere.

Leader shown using Generative AI on his laptop.

Every day, we're told that AI will transform business, automate work, and redefine how organizations operate. Some predictions are exciting. Others are alarming. Many are exaggerated.

For project and program leaders, the real question isn't whether AI will change how we work, the question is:


How can we use AI responsibly to improve organizational outcomes without sacrificing critical thinking, leadership, and sound decision-making?


After working with project teams, leaders, and organizations across all sorts of industries, I've come to a simple conclusion:

Generative AI is not a replacement for strong thinking. It is a tool that can help thoughtful professionals think better, work faster, and make more informed decisions; provided they don't take shortcuts.

The organizations realizing the greatest value from AI are not replacing people. They are empowering people to use it as a tool to accelerate their productivity and have more time to leverage their judgement.


The Evidence Is Clear


Much of the public conversation about AI focuses on automation and job displacement. Yet the research tells a different story.


A study conducted by researchers from Stanford University and MIT involving more than 5,000 professionals found that employees using Generative AI improved productivity by approximately 14 percent overall. Less experienced workers saw improvements as high as 35 percent. The technology did not replace employees; it helped them perform more like top performers.

Similarly, Microsoft's Work Trend research found that business leaders are far more interested in using AI to improve productivity than to reduce headcount. Employees using AI reported saving time, increasing focus on higher-value work, improving creativity, and experiencing greater job satisfaction.


McKinsey estimates that Generative AI could create trillions of dollars in annual productivity gains across industries. Yet McKinsey's research also emphasizes that value is realized when organizations redesign work around a partnership between humans and AI, not when they attempt to remove humans from the process.


The lesson is straightforward: The greatest value of AI comes from combining machine efficiency with human judgment.


Why Leaders Should Pay Attention


Project managers and program leaders spend much of their time performing activities that AI can accelerate:

  • Reviewing information

  • Drafting communications

  • Preparing reports

  • Identifying risks

  • Evaluating alternatives

  • Facilitating decision-making

  • Organizing stakeholder input


These activities remain essential, but they are often time-consuming. Generative AI allows leaders to spend less time creating information and more time analyzing it:

  • Less time formatting

  • More time leading

  • Less time gathering information

  • More time making decisions

  • Less time documenting problems

  • More time solving them


Where AI Creates the Greatest Value


The most successful organizations are using AI to support, not replace three critical leadership activities.


1. Identifying Risks Before They Become Problems

Most project teams identify obvious risks. Fewer identify the risks that haven't yet been considered. AI can serve as an independent reviewer that challenges assumptions and uncovers blind spots.


Prompt Example:

"Act as a senior program reviewer with experience leading large technology, operational improvement, and business transformation initiatives. Review the following project summary and identify 15 risks the project team may be overlooking. Categorize each risk, explain why it matters, identify early warning indicators, and recommend mitigation actions."


This approach frequently reveals stakeholder concerns, resource constraints, dependencies, organizational resistance, and operational impacts that might otherwise remain hidden until they become issues.


2. Improving Stakeholder Communication

Projects rarely fail because schedules exist. Projects fail because people misunderstand expectations, resist change, or lack alignment. AI can help leaders tailor communications for different audiences.


Prompt Example:

"Act as an experienced change management advisor. Rewrite the following project update for executives, managers, and frontline employees. Identify the concerns each audience is likely to have, the messages most important to them, potential objections, and recommendations for communicating effectively."


The result is more targeted communication, improved stakeholder engagement, and greater organizational alignment.


3. Strengthening Decision-Making

One of the most powerful uses of AI is not generating answers. It is challenging assumptions.

Strong leaders do not seek validation. They seek clarity.


Prompt Example:

"Act as an independent executive review board. Analyze the following recommendation and identify hidden assumptions, unintended consequences, second-order effects, risks of inaction, and alternative approaches. Present arguments both for and against the recommendation."

Used properly, AI becomes a constructive skeptic that helps teams make more informed decisions before committing significant resources.


What High-Performing Organizations Are Doing Differently

Organizations that are seeing meaningful value from AI tend to follow several common practices.


AI Drafts. Humans Decide.


AI is often used to generate first drafts of plans, reports, communications, analyses, and recommendations.


Humans review, refine, validate, and approve the final product.


The accountability remains with people.


Use AI to Challenge Thinking, Not Confirm It


Many professionals unintentionally use AI to validate ideas they already support. The best leaders use AI to expose weaknesses in their thinking. They ask AI to identify flaws, alternative perspectives, and hidden risks.


Maintain Human Accountability


AI can recommend.

AI can summarize.

AI can analyze.

But AI cannot own outcomes.

Successful organizations maintain clear human ownership for decisions, approvals, and accountability.


Use AI to Elevate Team Capability

Research suggests AI often provides the largest productivity gains for less experienced professionals.


Organizations are using AI to help team members think more like experienced practitioners by improving planning, communication, risk identification, and problem-solving.


A Simple Framework for Responsible AI Use

Project leaders do not need a complicated methodology to begin leveraging AI effectively.

A simple framework is often enough.


Ask

Generate ideas, alternatives, risks, assumptions, and options.


Analyze

Evaluate patterns, trade-offs, dependencies, and implications.


Assess

Apply experience, organizational context, stakeholder knowledge, and professional judgment.


Act

Make decisions, accept accountability, and execute.

AI can significantly enhance the first two steps.

Leadership remains essential for the last two.


The Future Belongs to Leaders Who Learn to Think With AI

Throughout my career, I've seen organizations invest heavily in tools while underestimating the importance of people.


There is a lesson to be learned from Lean Thinking where respect for people is a foundational principle. Building on this, the first value in Agile is to value, "Individuals and interactions over processes and tools".


What these really refer to is getting the culture right, where people drive the decision making and benefit because of the tools they have available to help them. They understand the tools won't save them.


Generative AI should not become another example. The organizations that will benefit most from AI are not those seeking to replace human expertise, they are seeing to enhance it. People make better decisions, and they make them faster.


They are those seeking to amplify it. Technology can process information faster than people. It can identify patterns, generate options, and accelerate routine work.

  • But it cannot replace judgment.

  • It cannot replace leadership.

  • It cannot replace accountability.

  • And it cannot replace the ability to navigate uncertainty, build trust, resolve conflict, and make difficult decisions.


Those responsibilities will remain firmly in human hands. The future does not belong to leaders who compete against AI, it belongs to leaders who learn how to think with it. When used thoughtfully, Generative AI becomes more than a productivity tool. It becomes a catalyst for better decisions, stronger collaboration, and ultimately, better project outcomes.



How this Lean Principle Creates Sustainable Agile Delivery


Many organizations associate Heijunka with manufacturing assembly lines, but its underlying principle, leveling work to create predictable flow and reduce waste caused by uneven demand, aligns remarkably well with Agile delivery.


What is Heijunka?


Heijunka (平準化) is a Lean concept often translated as:

Production Leveling or Workload Leveling

Its purpose is to smooth the flow of work by reducing:

  • Overburden (Muri)

  • Unevenness (Mura)

  • Waste (Muda)


Instead of processing large batches of one type of work followed by large batches of another, work is distributed more evenly over time.


Think of it as:

"Delivering a sustainable flow of value rather than responding to every priority change with chaos."

Why Agile Teams Should Care

Agile frameworks such as Scrum, XP, FDD, Kanban, SAFe, and others are fundamentally concerned with:

  • Sustainable pace

  • Predictable delivery

  • Continuous value delivery

  • Reduced bottlenecks

  • Improved quality


These goals are exactly what Heijunka supports. Without realizing it, many Agile teams suffer from the opposite of Heijunka:

Common Symptoms


Sprint 1:

  • 80% feature development

  • Little testing


Sprint 2:

  • Massive testing effort

  • Numerous defects


Sprint 3:

  • Emergency bug fixes

  • Technical debt cleanup


Sprint 4:

  • New feature rush


The result is:

  • Burnout

  • Unpredictable velocity

  • Defects

  • Missed commitments

  • Frustrated stakeholders


Heijunka seeks to create a smoother, more sustainable pattern.


Heijunka in Scrum

Consider a Scrum team developing a SaaS application.


Without Heijunka

Sprint Backlog:

Work Type

Story Points

New Features

45

Defects

0

Technical Debt

0

Refactoring

0

The team delivers many features.

Then defects emerge.

The next sprint becomes a bug-fixing sprint.

Velocity fluctuates wildly.

Stakeholders lose confidence.


With Heijunka

The Product Owner intentionally levels work.

Sprint Backlog:

Work Type

Story Points

New Features

25

Defects

5

Technical Debt

5

Refactoring

5

Architecture Improvements

5

The team delivers fewer features initially.

However:

  • Quality improves

  • Velocity stabilizes

  • Defects decline

  • Technical debt remains manageable

  • Stakeholder expectations become predictable

This is Heijunka applied to Scrum.


Practical Software Development Example

Imagine a company developing a cloud-based Customer Relationship Management (CRM) platform.


The Product Owner receives requests from:

  • Sales

  • Marketing

  • Customer Support

  • Compliance

  • Security


Without leveling, the team might spend:


Month 1

Building sales features


Month 2

Fixing defects


Month 3

Addressing security findings


Month 4

Supporting compliance requirements


This creates a cycle of constant disruption.


Applying Heijunka

The team creates delivery categories:

  • New Features

  • Defects

  • Security

  • Technical Debt

  • Compliance


For every sprint:

Category

Allocation

Features

60%

Defects

15%

Security

10%

Technical Debt

10%

Compliance

5%

Every sprint contains a balanced mix.


Benefits:

  • Security risks are continuously reduced

  • Technical debt never becomes overwhelming

  • Compliance work remains current

  • Defects are addressed regularly

  • Feature delivery continues


The workflow becomes smooth and predictable. That is Heijunka.


Heijunka and Extreme Programming (XP)


XP encourages:

  • Continuous Integration

  • Test-Driven Development

  • Refactoring

  • Small releases


These practices naturally support Heijunka because they prevent work from accumulating in large batches.


Rather than:

Build → Build → Build → Test

XP encourages:

Build → Test → Refactor → Integrate → Repeat

The work remains balanced.


Heijunka and Feature Driven Development (FDD)


FDD focuses on delivering features in small increments. A common risk is prioritizing only visible customer features.


Heijunka encourages balancing:

  • New features

  • Architectural improvements

  • Quality improvements

  • Defect correction


This creates healthier long-term delivery performance.


Heijunka and Agile Capacity Planning

One of the simplest ways Agile teams can implement Heijunka is through capacity allocation.


For example:

Team Capacity Allocation

  • 60% New Features

  • 15% Technical Debt

  • 10% Defects

  • 10% Innovation

  • 5% Learning and Skill Development


This prevents teams from constantly switching between "feature mode" and "cleanup mode."


The Hidden Benefit: Predictability


Most executives don't care whether a team uses:

  • Scrum

  • XP

  • FDD

  • Kanban

  • SAFe


What they care about is:

  • Predictable delivery

  • Consistent quality

  • Reliable commitments


Heijunka directly contributes to all three.


A team that consistently delivers 20 quality features every sprint is usually more valuable than a team that delivers:

  • 40 features

  • Then 5

  • Then 30

  • Then 10

with varying quality.


Key Takeaway


Many people think of Heijunka as a manufacturing tool. It isn't. It is a flow management principle.

Whether you're building automobiles, developing software, implementing cybersecurity controls, or managing a digital transformation project, the same lesson applies:

Sustainable, balanced flow almost always outperforms bursts of heroic effort followed by recovery.

For Agile teams, Heijunka means intentionally balancing features, defects, technical debt, security, compliance, learning, and innovation so that value is delivered continuously, predictably,

and sustainably.


In that sense, Heijunka may be one of the most underutilized Lean concepts in modern Agile software development.



They don’t make headlines the way a flashy product launch does. But behind some of the most resilient, profitable, and people-centered organizations in the world, you’ll find the same two disciplines quietly doing the work.


A PRACTITIONER’S PERSPECTIVE


There’s a question I often ask leaders when I first sit down with them: “Where does waste live in your organization?” Most pause. Some smile uncomfortably. A few are honest enough to admit they’ve never really looked. The ones who have looked, who have genuinely examined how their teams work, where time disappears, and why errors recur, are almost always the ones running the most effective organizations. And the tools they reach for, more often than not, are Lean and Six Sigma.


These methodologies are not relics. They were not born in a Silicon Valley co-working space or packaged as the latest management trend, but in 2026 they are as vital as ever, and evolving faster than most people realize. Lean traces its roots to Toyota’s production system in postwar Japan, a philosophy built around respect for people and the relentless elimination of waste. Six Sigma emerged from Motorola’s engineering floors in 1986, a disciplined, data-driven pursuit of near-perfect quality. What makes them enduringly relevant is not their age but their universality. Every organization, regardless of industry, size, or mission, has waste. Every organization has variation. And every organization has people who, given the right tools and the right culture, will rise to eliminate both.

 

“The goal is not to be better than the competition. It’s to be so well-organized internally that the competition becomes irrelevant.”

The spirit of continuous improvement

 

Part One

Lean: The Art of Freeing Up What Matters


At its heart, Lean is deceptively simple: identify what creates value for your customer, and eliminate everything else. Those “everything elses,” the unnecessary steps, the waiting, the redundant approvals, the overproduction, are what Lean practitioners call muda, the Japanese word for waste. And waste is everywhere once you train your eyes to see it.


Consider a hospital where nurses spend 40% of their shift searching for supplies instead of caring for patients. Or a software company where code reviews sit in a queue for three days because no one owns the handoff. Or a financial services firm where a loan application passes through eleven departments but only accumulates two hours of actual work. These are not failures of effort or intelligence. They are failures of process design. Lean gives organizations the language, tools, and permission to redesign them.


The cultural dimension of Lean is often undersold. When organizations implement it well, not as a cost-cutting exercise, but as a genuine operating philosophy, something remarkable happens to the workforce. People who have been executing the same broken process for years suddenly have a forum to say, “This doesn’t make sense, and here’s a better way.” That shift from passive executor to active problem-solver changes engagement levels profoundly and creates loyalty that no compensation package can fully replicate.

 

 

Part Two

Six Sigma: When Good Enough Isn’t Good Enough


If Lean asks “what shouldn’t we be doing?”, Six Sigma asks a harder question: “why do we keep getting it wrong?” Its ambition is almost audacious: no more than 3.4 defects per million opportunities. Not one percent error rates. Not industry averages. Near perfection, quantified and pursued systematically through a framework called DMAIC: Define, Measure, Analyze, Improve, Control.


What separates Six Sigma from well-intentioned improvement efforts is its insistence on data over instinct. Problems are not solved by consensus or by the opinion of the most senior person in the room. They are solved by evidence: baseline measurements, root cause analysis, statistical testing, controlled experiments. This rigor makes the improvements stick.


Today, 82% of Fortune 100 companies have implemented some form of Six Sigma, not as a legacy practice, but as an active operating discipline. And across Fortune 500 companies, Six Sigma adoption is credited with an estimated $427 billion in cumulative savings. These are not figures from a single era. They reflect decades of compounding application across industries that look nothing like a factory floor.

 

 

Part Three

A Universal Toolkit, and It’s Only Getting More Powerful


One of the most persistent myths about Lean and Six Sigma is that they belong on factory floors. They were born there, yes. But the principles that eliminate waste in a production line are just as potent in a hospital emergency department, a bank’s back office, a pharmaceutical lab, a government permitting process, or a startup’s customer onboarding flow. And in 2026, they’ve gained a powerful new amplifier: artificial intelligence.


The convergence of Lean Six Sigma with AI, IoT, and real-time data analytics is reshaping what’s possible. AI tools now predict process bottlenecks and surface root causes that human teams couldn’t realistically detect. Digital twins allow organizations to simulate workflow changes before implementing them. What was once a periodic improvement exercise is becoming, as consultant Albert Adusei Brobbey wrote in Healthcare IT Today (2026), “a system of continuous intelligence.”


 

 

In healthcare, the stakes of waste and variation are not just financial; they are human. Mount Sinai Health System applied AI process mining tools within a Lean Six Sigma framework to map their entire patient discharge pathway end-to-end. What they found surprised many: the biggest delays were not clinical. They were paperwork and coordination gaps. Fixing those administrative chokepoints cut average discharge times by roughly 22%, with the downstream effect of opening beds faster and easing emergency department pressure. At Mayo Clinic, predictive machine-learning models now work alongside Lean Six Sigma teams to forecast surgical durations and flag likely cancellations before they happen, a capability that has trimmed idle operating room time by up to 15% (Healthcare IT Today, 2026).


In financial services, McKinsey research shows that Lean Six Sigma has driven productivity increases of between 20% and 150% in financial institutions, a remarkable range that reflects how transformative the methodology can be when organizations commit to it fully rather than applying it at the edges. In pharmaceuticals, a firm in Hyderabad leveraged Lean Six Sigma to reduce batch release time from 12 days to 7, accelerating product launches and increasing capacity without a single rupee of additional capital investment.


And in a 2024 study on online education, perhaps the most surprising application of all, Lean Six Sigma reduced administrative turnaround times by 42.9% and measurably improved course quality ratings. If it works in a digital learning environment, it works anywhere.

— ✶ —

Part Four

The Culture Beneath the Toolkit


Here is what the statistics can’t fully capture: what happens to people inside organizations that genuinely embrace these methodologies. Not as mandates handed down from leadership. Not as rebranding exercises for headcount reduction. But as a shared commitment to doing the work better, together.


Lean, at its philosophical core, is built on two pillars: continuous improvement and respect for people. The second pillar is the one most organizations underinvest in. Respect for people means trusting frontline employees to identify problems, authority to test solutions, and credit when improvements land. It means that the person doing the work is also the person improving the work. That dynamic, when it takes root, creates a self-reinforcing culture that no competitor can easily replicate.


Six Sigma’s certification structure (Yellow Belt, Green Belt, Black Belt, Master Black Belt) creates something equally powerful: a shared language and a visible pathway for professional growth. When everyone understands what “root cause analysis” means, what “voice of the customer” requires, and why data must precede diagnosis, conversations about performance improve dramatically. Decisions move faster. Debates get shorter. Solutions last longer. And individuals gain skills that serve them and their organizations across their entire careers.


Research on sustained Lean management found that the key to longevity is not the tools; it’s the culture they enable. Organizations that build genuine improvement cultures, where continuous learning is expected, where employees have real voice, and where leaders model the methodology rather than merely mandate it, sustain their gains far beyond initial implementation.

 

“Lean isn’t about doing more with less. It’s about doing better with what you have, and then discovering you actually need less.”

 

Part Five

The Question Worth Asking


I’ve worked with organizations across industries, and the ones that thrive, not just for a quarter, but across years and market cycles, share a particular trait. They are relentlessly curious about their own processes. They ask uncomfortable questions: Why does this take two weeks when the actual work takes two hours? Why does this error keep happening when we’ve “fixed” it three times? What would our customers say if they could see exactly how we operate?


Lean and Six Sigma are not magic. They require commitment, patience, and leadership that is willing to look critically at the status quo. But the payoff, in performance, in culture, and in the satisfaction of doing genuinely excellent work, is hard to match through any other means.


Whether you lead a ten-person startup or a ten-thousand-person enterprise; whether you work in surgery suites or server rooms; whether you manage money, code, patients, supply chains, or students, the fundamentals apply. Waste is universal. Variation is universal. And the human desire to do good work, when properly channeled, is universal too.


These are not just tools. They are a way of seeing, and once you see through them, you cannot un-see the opportunity they reveal.


— ✶ —


Interested in exploring how Lean or Six Sigma might apply in your organization? I offer focused training sessions in each methodology, built around real-world application, not just theory.

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