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John Knotts

As a Lean Six Sigma Master Black Belt, John has over 30 years of experience in operational excellence. He served 21 years in the US Air Force -- 11 as an internal coach and consultant. He led strategy and change efforts with Booz | Allen | Hamilton for 18 clients. He was an internal coach and consultant for Fortune 100, United Services Automobile Association. And, he’s been a solopreneur growing, scaling, and improving companies for over 12 years. In addition to multiple certifications in change management, project management, agile, and information technology, John has a Bachelor’s in Management, a Master’s in Quality Systems Management, and a Ph.D. in Industrial and Organizational Psychology.

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33 Articles

Micromanagement Is Not Respect for People

By John Knotts - October 8th, 2025

Micromanagement is one of the most common leadership pitfalls in the workplace. According to a survey by staffing agency Accountemps, 59% of employees reported having worked under a micromanager. Most managers do not set out to be micr

Using Fault Tree Analysis (with AI) to Fireproof Your Home

By John Knotts - July 25th, 2025

After over 35 years working in process improvement, I’ve applied tools like Fault Tree Analysis (FTA) in everything from factories to boardrooms. But it wasn’t until recently that I asked myself: Why not use FTA at home? That simpl

New ways of working text on yellow notepad

Agile Process Improvement Efforts

By John Knotts - September 20th, 2024

In today’s leaner times, businesses are often forced to scrutinize their investments, and unfortunately, process improvement programs like quality initiatives are frequently among the first to be cut. These programs are often per

Man on a boat fishing for tuna fish in the North Atlantic ocean.

Are You Keeping The Line Wet?

By John Knotts - August 23rd, 2024

Last week, during a Gemba Academy Lean Bootcamp, Ron Pereira talked about “keeping the line wet” when teaching. This was a new term to me, but I found it to be an important term. “Keep the line wet” is a phrase

Why Sigma?

By John Knotts - August 2nd, 2024

I was asked a question that I had never been asked before: “Why Sigma: Why is only Sigma in Lean Six Sigma Yellow and Green & Black belt? Why not use Alpha, etc…?” Honestly, no one had ever asked me that question befo

A Company’s Continuous Improvement Journey

By John Knotts - July 19th, 2024

Embarking on your company’s continuous improvement journey can often be frustrating. This leads to the disheartening realization that your efforts seem ineffective. In the pursuit of excellence, many companies embark on a journey

Unlock Your Potential with Gemba Academy’s Master Black Belt Program

By John Knotts - June 21st, 2024

Are you ready to elevate your career and become a strategic leader in Lean and Six Sigma methodologies? Gemba Academy’s Master Black Belt (MBB) program is your pathway to mastering continuous improvement and driving significant b

Aligning 5S and DMAIC for Process Improvement

By John Knotts - May 17th, 2024

All too often, process improvement coaching candidates struggle to find practical and effective process improvement ideas to use for their certification projects. I often recommend integrating two well-established methodologies: 5S and

Enhancing Organizational Efficiency through Supplier Process Improvement

By John Knotts - April 19th, 2024

In an increasingly interconnected business ecosystem, the performance of an organization is not solely determined by its internal processes but also by the efficiency and reliability of its suppliers. The concept of working closely wit

Process Improvement Across Industries

By John Knotts - March 15th, 2024

In the realm of business and organizational efficiency, understanding the nuances of process improvement across various industries is not merely an exercise in intellectual curiosity but a necessity. With 34 years of experience in this

Understanding the Customer Experience is a Keystone in Process Improvement

By John Knotts - February 16th, 2024

In the realm of business, the adage “the customer is always right” has evolved into a more nuanced understanding that “the customer’s experience is paramount.” As we dive deeper into the intricacies of cus

Embracing System-Level Problem Solving over Firefighting

By John Knotts - January 19th, 2024

In the dynamic landscape of business and organizational management, problem-solving is often equated with ad hoc firefighting – a reactive approach where individuals scramble to douse the flames of immediate issues. While this method

Is Process Improvement Certification Right For Me?

By John Knotts - November 17th, 2023

Embarking on a journey of process improvement often leads to the crossroads of certification. Is obtaining a process improvement certification the correct path for you? This question resonates with many professionals who are eager to e

Robot humanoid using tablet computer for global network connection

Harnessing AI Large Language Models for Process Improvement

By John Knotts - October 20th, 2023

Artificial Intelligence (AI) is on everyone’s lips these days. In the realm of AI, Large Language Models (LLMs) are emerging as pivotal tools capable of understanding and generating human-like text. However, the capability extends fa

Are You Seeing Green?

By John Knotts - September 22nd, 2023

A “Green Process,” in the context of business and manufacturing, refers to a method or strategy that is designed to have a minimal negative impact on the environment. This can encompass a wide range of efforts aimed at redu

Implementing 5S in Your Company

By John Knotts - August 18th, 2023

In an era where business competition is fierce, having a streamlined operation can give you a significant edge. One effective strategy to achieve operational efficiency is the 5S methodology. But how do you know if your company needs 5

Conducting A Manual Process Assessment

By John Knotts - July 21st, 2023

A manual process is a task or procedure that is performed without the assistance of automation or technology. These tasks typically require human effort, physical actions, and direct input. Manual processes can range from simple tasks,

The Power of Creativity in Process Improvement Projects

By John Knotts - June 16th, 2023

In today’s fast-paced and competitive business environment, organizations are constantly seeking ways to improve their processes to stay ahead of the curve. While traditional process improvement methodologies play a crucial role,

Maximizing Efficiency with Warehouse Control

By John Knotts - May 19th, 2023

In today’s fast-paced business world, effective warehouse management is crucial for maintaining a competitive edge. A well-organized and controlled warehouse can significantly impact overall operational efficiency, customer satis

Employee workplace

5S and Spring Cleaning

By John Knotts - April 21st, 2023

What better time than now to talk to you about spring cleaning and 5S? Now, you may be wondering what exactly 5S is, and how it relates to spring cleaning. Well, let me explain. 5S is a methodology used in manufacturing and other indus

Finding Process Improvement Opportunities

By John Knotts - March 17th, 2023

Large organizations that employ process improvement departments and teams often have a list of process improvement projects (typically called the “1 to n list”). These potential projects are prioritized, and practitioners simply ha

meeting

Conducting Engaging Virtual Meetings

By John Knotts - February 17th, 2023

In process improvement, it is always best to involve a team. This helps get different points of view and perspectives on a problem. Also, having a team means that you have more people to help you do the work — especially when it

Measuring The Pig In The Python

By John Knotts - January 20th, 2023

Data collection and analysis are critical in process improvement. Data shows progress in process improvement over time and serves as a barometer of process effectiveness and efficiency. Measuring a straightforward process that takes se

Quick Way To Time A Process

By John Knotts - December 16th, 2022

Understanding and measuring process time is one of the most important aspects of process improvement. Much of the waste (muda) in a process causes a process to take longer than it should. When a process takes longer, customers are wait

Going To The Electronic Gemba

By John Knotts - November 18th, 2022

Going to Gemba — where the work is done — is a pretty simple concept. Go where the work is being performed and watch what is happening. What happens when the process is all online?  Where everything that is happening, is o

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