Michigan Lean Consortium MLC Community Column

Where Strategy Meets Honesty: Recapping the 8th Annual Grand Rapids Lean Summit

Fri, 20 Mar 2026 18:09:44 GMT

A few weeks ago we gathered at Grand Valley State University for the 8th Annual Grand Rapids Lean Summit, themed Align & Communicate: Leading with Purpose and Honesty. From a keynote that reframed communication as a human discipline, to breakout sessions connecting Hoshin Kanri and ethical AI, to a student competition that had the room on its feet, this was a summit that reminded everyone why showing up in community matters.

Setting the Stage: The People Who Make It Happen

A day like this doesn’t run itself. Serving as Mistress of Ceremonies, Debra Levantrosser kept the energy high, the audience engaged, and the day running flawlessly from start to finish.

We had a dedicated group of MLC Champions in attendance whose commitment to the organization makes events of this scale possible: Brian DeVries, Patrick Adams, Jerry Browne, and Dennis Sergent. A special note on Dennis Sergent: in addition to his champion contributions, Dennis has recently stepped up to help develop and lead the MLC Ambassador Program, a new initiative to extend MLC’s reach and deepen practitioner connections across Michigan.

The summit was beautifully documented by photographer Maggie Rothney. Volunteers Kim Egan and Shawna Alejos gave generously of their time to ensure a smooth and welcoming experience, thank you.

The day would not have been possible without our sponsors, and special recognition goes to Diamond Sponsor Lean Solutions, whose investment in this community exemplifies the spirit of continuous improvement.

The Keynote: Radical Honesty as a Leadership Discipline

Ken Bogard, bestselling author of Know Honesty and self-described "Open and Honest Expert" opened the summit with a session that challenged the room to rethink communication from the ground up. His presentation, "Solving Every Leadership Team's #1 Problem — Communication," drew a sharp and memorable line between talking and truly communicating.

Breakout Sessions: Tools You Can Use Monday Morning

Three breakout sessions each offered a distinct and practical perspective on alignment, communication, and continuous improvement.

Jennifer Schoenherr, Lean and Six Sigma Manager at Ford Motor Company, introduced cartooning as a surprisingly powerful problem-solving tool.

Christopher Davis, Technology Analyst at Consumers Energy and founder of Country Roads Data Consulting, tackled one of the defining questions of the AI era: Is your organization using AI to amplify human capability or as a crutch masking systemic weakness?

Dawn Armfield, Senior Director of Operational Diligence Services at Hilco, brought more than three decades of manufacturing expertise to her Hoshin Kanri session. Her premise was pointed and practical: most organizations don't lack strategy — they lack traction.

The summit also brought exciting news for the MLC community. We are thrilled to announce that Dawn has accepted the role of MLC Outreach Director for 2026.

Student Competition: The Future of Lean Is in Great Hands

If one activity captured the spirit of the day, it was the Lean Student Competition. Teams from Grand Valley State University, the University of Michigan, and Western Michigan University went head-to-head in a live Kaizen-style challenge, building towers from marshmallows and spaghetti while iterating through rapid PDCA cycles under real constraints and a ticking clock.

Western Michigan University took home the top prize, earning well-deserved recognition for their performance across the competition. But the contest revealed something richer than a single winner. The University of Michigan team achieved both the tallest final build and the highest performance improvement across iterations, demonstrating the power of disciplined learning cycles. Grand Valley State University brought fierce creativity and energy throughout, representing their home institution with pride.

Watching students adjust, experiment, and improve in real time was, for many in the room, the high point of the summit. The future of Lean is in great hands.

Thank you to every speaker, sponsor, volunteer, student, and practitioner who made the 8th Annual Grand Rapids Lean Summit a day to remember. The Michigan Lean Consortium is a membership-based nonprofit in its 17th year. To learn more or become a member, visit www.michiganlean.org/join.

Hidden in Plain Sight: How Fibre Converters Brings Lean to Life Behind the Scenes

Fri, 20 Mar 2026 15:29:36 GMT

There’s a good chance you encountered something Fibre Converters made today. You just didn’t know it and that’s exactly the point.

The Constantine, Michigan-based manufacturer has spent more than 75 years perfecting the art of the invisible, producing laminated paper, die cut components, and extrusion-coated materials that quietly hold the world together. The paperboard tucked behind your car seat. The structural panel behind a dresser drawer. Fibre Converters makes all of it, and more.

Founded in 1949, the company has grown into a privately held operation with just over 100 employees, large enough to carry serious technical expertise, small enough to stay nimble and responsive. And if there’s one thing they’ve committed to, no matter where they are in the journey, it’s continuous improvement.

The System Behind the System

The Fibre Transformation System (FTS), as the team calls it, is the backbone of how improvement happens across the organization. It isn’t a poster on the wall or a quarterly initiative. It’s a structured framework with tools, governance, and clear processes for identifying opportunities, prioritizing work, and sustaining results. It’s designed so that employees at every level can engage with it.

Leading that effort is Kayla Rudy, FTS Manager and the person responsible for both building and deploying the system. Her role sits at the intersection of structure and people: making sure the right tools are in place while building the kind of cross-functional collaboration that makes lasting improvement possible.

But Kayla is quick to point out that none of it happens without the people around her. The operators and team members on the floor are the ones who bring the system to life every day, problem-solving, asking questions, and doing the hard work of improvement in the middle of everything else on their plates. FTS is built for them, and because of them.

A Lean Community, Found at the Right Moment

In the fall of 2024, Kayla attended the Lean Leadership Summit on the advice of their Green Belt instructor, Jerry Browne. It was her first MLC event, but it wasn’t her last. Since then, she’s attended the Grand Rapids Lean Summit, participated in Gemba Tours, and became a regular at the virtual coffees that MLC hosts throughout the year.

What started as one person exploring a new community has grown into something more meaningful for the organization. Fibre Converters has since added their FTS Technician and three engineers to their MLC membership, with those engineers currently enrolled in the MLC Green Belt Course this spring.

That kind of expansion isn’t accidental. It reflects a deliberate decision to invest in the people who will carry the improvement work forward.

Learning by Doing—and by Listening

One of the things that keeps Fibre Converters coming back to MLC events isn’t just the content, it’s the conversations that happen around it.

Through the MLC, the team has connected with organizations across industries, gaining real-world insight into how other practitioners apply Lean principles in very different environments. That cross-pollination matters. When you see how a completely different operation has solved a problem you’re wrestling with, it opens up possibilities you might not have considered on your own.

Fibre Converters has taken that seriously. They haven’t just attended events, they’ve actively adapted what they’ve learned, incorporating ideas from other organizations into their own continuous improvement efforts. There’s still plenty of road ahead, but that willingness to borrow, adapt, and apply is exactly what the MLC is here for.

“To say my fate is not tied to your fate is like saying, ‘Your end of the boat is sinking.’”

We’re All in the Same Boat

That quote cuts to the core of why they approach continuous improvement the way they do. Every role matters. Every process is connected. Every decision ripples outward to affect what gets delivered to customers.

For Fibre Converters, building a stronger organization means building better systems and stronger people simultaneously. The Fibre Transformation System provides the structure. MLC provides the community, the tools, and the broader perspective that helps the team keep growing.

We’re proud to have Fibre Converters as part of the MLC community. Here’s to the continuous improvement journey, one that, as they know well, is always better traveled together.

About Fibre Converters

Based in Constantine, Michigan • Founded 1949 • Specializing in laminating, die cutting, and extrusion coating

www.fibreconverters.com

Retirement Spotlight: Jim Willems, State of Michigan

Fri, 20 Feb 2026 15:19:36 GMT

Please join us in congratulating Jim Willems on his retirement after many years of dedicated service to the State of Michigan and his meaningful contributions to the Michigan Lean Consortium (MLC).

Throughout his career, Jim has exemplified a genuine commitment to making life better for others. His work has consistently focused on improving how government serves its residents—ensuring processes are not only efficient but also centered on people. His leadership and dedication have touched countless lives, both within state government and across the communities we serve.

Jim was a champion of the recently launched mentor program for the MLC Green Belt certification, a reflection of his passion for developing others and fostering a culture of continuous improvement.

His unwavering dedication to public service and ability to inspire those around him have left a lasting legacy. While we will miss his insight and guidance, we celebrate the tremendous impact he has made and the example he has set for all of us.

Looking Ahead: What to Expect in 2026

Mon, 12 Jan 2026 13:32:20 GMT

As we look toward 2026, the Michigan Lean Consortium is focused on deepening connection, expanding access, and strengthening capability across Michigan’s Lean community. Building on the momentum of 2025, the year ahead brings renewed leadership, the return of favorite programs, and thoughtfully designed learning experiences that support both people and systems.

At its core, 2026 is about creating spaces where Lean practitioners can learn together, challenge assumptions, and build lasting relationships—while continuing to grow the skills needed to lead meaningful improvement.

Leadership & Student Engagement

We are honored to welcome Dr. Debra Levantrosser as MLC’s Higher Education Programs Director in 2026.

A full-time faculty member at the University of Michigan College of Engineering (Industrial & Operations Engineering), Dr. Levantrosser brings more than 35 years of executive and international leadership experience spanning global supply chains, Lean strategy deployment, executive education, and leadership development. As the founder of the Michigan Lean Consortium, her return to Board leadership represents a meaningful full-circle moment. Her passion for student engagement and real-world application of Lean principles will play a key role in developing the next generation of Lean leaders across Michigan.

Alongside Dr. Levantrosser, the MLC is guided by a dedicated Board of Directors committed to strengthening the organization, expanding access to Lean learning, and supporting members across the state:

Chair: Pamela Burgess
Vice Chair: Melissa Sherman
Treasurer: Dr. Patricia Malone
Secretary: Chenoa Reyes
Membership Director: Kim Ziegler
Training Director: Josh Smith

Together, this leadership team brings a wide range of experience across industry, education, healthcare, and the public sector.

A Call to Lead: Interim Board Opportunities

As we grow, so does the opportunity to lead. The Michigan Lean Consortium is currently seeking three engaged members to serve as Interim Directors for Events and Outreach, with terms running through December 31, 2026.

These volunteer leadership roles are well-suited for members who enjoy building community, shaping programming, and strengthening relationships across the Lean ecosystem.

Open Focus Areas Include:

Large Events (Conferences & Summits)
Small Events (Virtual Coffees & Gemba Walks)
Outreach (Relationship Building & Partnerships)

If you’re interested in giving back, growing as a leader, and helping shape MLC’s future, we encourage you to learn more and apply. Details and application instructions are available on our website.

Signature Events & Programs Returning in 2026

Lean Reads & Reflections

Back by popular demand, the MLC Book discussions now called Lean Reads & Reflections returns in 2026 as a space for shared learning, reflection, and thoughtful conversation. Designed to connect theory to practice, these events offers a relaxed, community-centered way to explore ideas and learn from one another.

8th Annual Grand Rapids Lean Summit

Friday, March 6, 2026
GVSU L.V. Eberhard Center

In a time of constant change, alignment and communication are not optional—they are essential. The 2026 Grand Rapids Lean Summit will focus on how organizations can move strategy into action through hoshin kanri, while cultivating transparent, trust-based communication that drives engagement, innovation, and sustainable results.

Participants will gain practical tools and real-world insights to:

Translate strategic goals into clear, actionable priorities
Strengthen alignment across teams, departments, and leadership levels
Practice honest, purpose-driven communication that builds trust
Reduce confusion, silos, and rework through clearer execution
Lead change with integrity in complex, people-centered systems

2026 MLC Annual Conference

Navigating Lean: Anchored in Connection
August 4–7, 2026
VanDyk Mortgage Convention Center
460 W Western Ave, Muskegon, MI

Set along Michigan’s lakeshore, the 2026 Annual Conference will bring Lean practitioners together to explore how connection—between people, strategy, and purpose—anchors sustainable improvement. Expect immersive learning, meaningful networking, and inspiration grounded in real-world practice.

Lean Six Sigma Green Belt Course – Returning in 2026

For those ready to deepen their practice, the Lean Six Sigma Green Belt Course returns in 2026, facilitated by expert instructor Jerry Browne.

This blended learning course runs February–July 2026 and is designed to meet the requirements of ISO 18404 certified Lean Practitioner & Six Sigma Green Belt. Participants gain hands-on experience, practical tools, and coaching support to apply Lean Six Sigma methods directly within their organizations.

Moving Forward with Purpose

From leadership development and student engagement to statewide events and professional certification, 2026 is shaping up to be a year of connection, clarity, and capability-building.

We look forward to continuing this work with you—strengthening Michigan’s Lean community, one improvement at a time.

2025 Year in Review

Mon, 29 Dec 2025 14:55:32 GMT

Building Community. Strengthening Systems. Advancing Lean Across Michigan.

As we close out 2025, we’re proud to reflect on a year of growth, connection, and intentional progress at the Michigan Lean Consortium. This year marked an important chapter—defined by thoughtful change, renewed energy, and a deepened commitment to serving Lean practitioners across Michigan.

Here’s a look at what we accomplished together.

Strengthening Our Foundation

In early 2025, the MLC Board took meaningful steps to better align our structure with our long-term vision. We clarified board roles, aligned a more intentional and transparent election cycle, and began updating our bylaws to reflect who we are today and where we’re headed.

One of the most impactful shifts was aligning the Board Call for Nominations with the Annual Conference—giving members greater transparency and the opportunity to hear directly from Board leadership before applying. This change reinforces our commitment to openness and member-driven governance.

Operations, Technology, and Brand

Behind the scenes, we leaned into continuous improvement—strengthening operational systems, improving communication, and enhancing professionalism across the organization. Members can now opt in to receive text updates for events and membership reminders, expanding how we stay connected.

Click Here to opt in for Text Messaging

Visually, we refreshed our brand with the return of the MLC blue and orange logo, inspired by Michigan’s open skies and fresh water. The updated look reflects clarity, growth, and inclusivity—core to who we are as a statewide Lean community.

Expanding Reach Across Michigan

In 2025, MLC continued to expand its reach by bringing Lean learning to more corners of the state. Rotating the Annual Conference to different regions increased accessibility while showcasing the diversity of Michigan’s industries, communities, and improvement stories.

We also strengthened our presence within the broader continuous improvement community by sponsoring and participating in events such as the Crusaders Connection Event and the Lean Solutions Global Summit, building new relationships and deepening existing partnerships.

This year marked the launch of several new learning opportunities, including the Lean Six Sigma Green Belt Course, facilitated by Jerry Browne. Running January–June 2025, the course meets ISO 18404 requirements and supports practitioners ready to advance their Lean capabilities.

In addition, MLC hosted its first-ever Lean Excellence Student Competition in partnership with Lean Solutions, engaging 14 students and faculty members, and highlighting the next generation of Lean leaders.

2025 By the Numbers

12 Monthly Virtual Coffees connecting practitioners statewide

6 In-Person Gemba Tours offering hands-on learning

Grand Rapids Lean Summit with 80 attendees

MLC Annual Conference with 120+ in-person participants

Average event rating: 4.6 (goal: 4.25)

Membership: Gained 140 new members

Hosted 38 Students and Faculty at no cost across virtual and in-person events.

Net revenue: Achieved a positive net financial outcome, exceeding initial financial expectations

Leadership & Volunteers

2025 brought leadership evolution, including a new board structure that expanded the Vice Chair role and added an Outreach Director—further supporting community engagement and statewide growth.

We are deeply grateful to our volunteers, whose dedication makes everything possible. This year, Heidi Sheffield was honored with the 2025 Distinguished Service Award for her outstanding contributions to the MLC.

Membership & Partnerships

We were excited to welcome new bundle members including Consumers Energy, Sebright Products, Orchid Orthopedic, and the University of Michigan, reflecting continued investment in Lean learning across sectors.

We also extend sincere thanks to the many sponsors and partners who supported MLC programming throughout the year—your partnership fuels learning, connection, and impact across Michigan.

This past year we launched the featured organization program for our members. This allowed our members to increase their reach and promote lean opportunities to the MLC community. We are excited to continue this program for 2026.

Learn More about the Featured Organization Program

Thank you to everyone who made 2025 such a meaningful year. Stay tuned for Part Two, where we’ll look ahead to what’s coming in 2026.

Member Spotlight: Gentex Takes First Place at the Global Lean Excellence Competition

Mon, 03 Nov 2025 12:56:13 GMT

Six members of Gentex Corporation’s Continuous Improvement team brought home first place honors from this year’s Global Lean Excellence Competition, held during the Lean Solutions Summit in Detroit this September.

Team Gentex—made up of Jeff Miles, Leslie Householder, Steve Burgett, Jordan Kimble, Justin Karsten, and Trent Davison—rose to the challenge in a fast-paced, hands-on test of Lean thinking and teamwork.

The competition tasked teams of process improvement professionals with transforming a broken process into one that was both efficient and high-quality, all under intense time pressure. This year’s challenge: create a streamlined system for assembling and delivering notoriously tricky IKEA cabinets.

Gentex’s team impressed judges with their ability to quickly analyze the problem, eliminate waste, and implement a standardized, efficient workflow—all while maintaining precision and collaboration. Their efforts earned them the top spot in the competition.

But the event wasn’t just about process improvement—it was about purpose. Once the challenge was complete, all of the assembled furniture was donated to House N2 Home, a nonprofit organization in Washtenaw County that helps furnish homes for individuals and families transitioning out of homelessness.

By combining Lean excellence with community impact, Team Gentex exemplified the heart of continuous improvement—making things better, not only in the workplace but also in the world around us.

Congratulations to Team Gentex on their well-earned victory and for representing Michigan’s Lean community with innovation, teamwork, and heart.

Recap: 2025 Lean Excellence Student Competition at the Lean Solutions Summit

Mon, 20 Oct 2025 14:47:34 GMT

Last month, the Michigan Lean Consortium (MLC) had an incredible experience at the Lean Solutions Global Summit in Detroit! The Lean Excellence Student Competition brought Lean learning to life as students showcased their commitment to continuous learning, scientific thinking, and teamwork.

The energy in the room was electric as two University of Michigan teams went head-to-head in a catapult systems challenge designed to test their Lean knowledge, collaboration, and problem-solving under real-world conditions. Each team worked to standardize processes, reduce variation, and demonstrate measurable improvement—all while having a blast.

In the end, it was the Blue Team that took home the victory—but the competition was incredibly close, with just a razor-thin margin separating the two teams.

“It was inspiring to watch these students bring Lean to life,” said one of our judges. “Their creativity, discipline, and collaboration show just how bright the future of Lean really is.”

Recognizing Our Supporters

This event would not have been possible without the incredible individuals and organizations that supported it:

Special Thanks To:

Debra Levantrosser – U-M Team Coordinator
Coaches: Ray Muscat, Mary Duck, and David Hyatt
Judges: Josh Smith, Pamela Burgess, and Jon Kuipers
Partner: Lean Solutions
Sponsors: ZFS Solutions, Mike Dixon (Utah State University), and S Post Consulting

Your dedication and support gave students a meaningful platform to learn, collaborate, and lead the Lean way.

Looking Ahead

The success of this year’s competition highlights the importance of connecting students with real-world Lean experiences. The MLC is excited to continue building this program—expanding opportunities for students across Michigan and beyond to engage with Lean thinking, industry mentors, and the wider continuous improvement community.

The future of Lean is bright—and we couldn’t be more excited to be part of it.

Featured Organization Spotlight: Brittany Parks Process Consulting (BPPC) & Energy Control Power Lockout (ECPL)

Mon, 06 Oct 2025 12:32:42 GMT

Brittany Parks Process Consulting (BPPC) and Energy Control Power Lockout (ECPL) exemplify how Lean thinking and safety excellence work hand in hand to create stronger, more resilient organizations.

At BPPC, the focus is on strengthening standard operating procedures through process improvement and organizational change management—helping teams drive consistency, efficiency, and long-term success. ECPL complements that work by delivering customized safety program solutions, including lockout/tagout placards, evacuation maps, and compliance signage. Together, BPPC and ECPL equip organizations with the systems, tools, and culture needed for safe, efficient, and sustainable operations.

As the Owner and Principal Consultant at BPPC and Owner and President of ECPL, Brittany Parks leads both companies in partnering with clients across manufacturing, government, healthcare, nonprofits, and small businesses—helping each create workplaces that protect people and perform at their best.

History with the MLC

Brittany has been an active member of the Michigan Lean Consortium (MLC) for several years, serving as a speaker, workshop leader, and participant. Both BPPC and ECPL have supported MLC events through sponsorship and thought leadership—particularly in advancing conversations around building strong safety cultures, applying Lean principles, and bridging the gap between compliance and continuous improvement.

Why We Choose to Be Members of the MLC

“Our ‘why’ is rooted in people,” Brittany shared. “We believe every worker deserves to return home safely and every organization deserves processes that work for them—not against them.”

The MLC provides a network where BPPC and ECPL can both learn and give back, exchanging best practices in Lean, safety, and leadership. Membership creates opportunities to connect with peers, spark collaboration, and stay at the forefront of improvement practices that benefit Michigan’s industries and communities.

“Through the MLC, we’ve seen firsthand how Lean principles not only improve efficiency but also create safer, more sustainable workplaces. That’s why both BPPC and ECPL are proud to be supporters—we are committed to shaping systems that protect people and improve performance.”
— Brittany Parks, Owner & Principal Consultant, BPPC; Owner & President, ECPL

A Human-Centered Approach to Continuous Improvement

At BPPC and ECPL, strong systems are built with people at the center. Their work integrates human-centered design with Lean and safety principles to ensure solutions are not only effective—but also intuitive, practical, and embraced by the teams who use them.

Beyond tools and templates, both organizations partner with clients to design and implement change management strategies that align operational efficiency with safety compliance. By focusing on how people interact with systems, BPPC and ECPL help create processes that last—driving meaningful, sustainable improvement.

As active members of the Michigan Lean Consortium, BPPC and ECPL embody the spirit of Lean leadership—combining innovation, safety, and collaboration to make Michigan’s workplaces safer, stronger, and better connected.

Reflecting on the 2025 MLC Annual Conference

Mon, 22 Sep 2025 12:20:21 GMT

Pamela Burgess, Chair of the 2025 Annual Conference, summed it up best: “The MLC community showed up. I’ve never experienced anything like it.”

As the team, board members, sponsors, and presenters arrived, what could have been chaos turned into a masterclass in collaboration. “No joke—anyone that was around just did what was needed,” Pamela shared. “I don’t think I carried anything beyond my luggage… actually, someone grabbed that too!”

✅ Check It Off the List!

✔️ 3 days of learning and Lean energy
✔️ 12+ breakout sessions across industries
✔️ High-impact keynotes and panels
✔️ Gemba Walks across Frankenmuth, Saginaw, and Bridgeport
✔️ White Belt Certification track
✔️ Interactive sessions that brought play and practice together
✔️ A room full of Lean learners, leaders, and legacy builders

Conference Highlights

Inspiring Keynotes

We kicked off with Alexandra Suchman, CEO of Barometer XP, who reminded us of the power of play in workplace culture. Her interactive session had us reflecting and thinking differently about how we approach continuous improvement.

Mark Cruth, Principal Modern Work Coach at Atlassian, took us into the future with a keynote on Lean + AI. His message: before you make a process faster, make the system better.

And throughout the week, Debra Levantrosser, MLC Founder, guided us with humor and heart as our conference emcee. A Lean legend who kept the flow moving—and the energy high.

Mix, Mingle, and Cruise

Wednesday’s Riverboat Cruise, sponsored by HilCo Global, was a chance to relax, reflect, and reconnect on the beautiful Bavarian Belle.

Breakouts, Panels, and Big Thinking

With over a dozen engaging sessions, we covered everything from Lean in government and healthcare to facilitation, communication, team dynamics, and strategy deployment.

Attendees raved about sessions from:

Patrick Adams (Lean Solutions)
Pamela Weiss (Orlans Law Group)
LaShira Champion-King (Walbridge)
Adam Lawrence (Process Improvement Partners)
Jaclyn Badder (State of Michigan)
Troy Tungate (GE Healthcare)
Sarah Tilkens
Liz Gardner
Jamie Noble
And so many more.

The White Belt Certification Track—led by Stephanie Welch and Jerry Browne—welcomed new learners into the Lean community with hands-on training and foundational tools.

Bonus Session: Big Thinking Box

One of the most memorable sessions came courtesy of Brian and Allison DeVries, who wrapped up the conference with The Big Thinking of a Small Knight. This engaging, story-driven experience blended creativity with Lean principles and left attendees inspired to take big thinking back to their teams and classrooms.

Friday Gemba Walks

To close out the week, attendees went out into the field for Gemba Walks at:

Frankenmuth Cheese Haus – Celebrating 50 years of flavorful innovation
‍ Amigo Mobility International – A showcase of people-first Lean improvements
Nexteer Automotive – A Lean leader in driveline technologies

Each location offered a unique perspective on Lean principles in motion, and participants left energized by seeing how continuous improvement thrives in different environments.

A Community That Shows Up

Pamela shared it all best:
“Was it perfect? No. Room for improvement? Absolutely. But I couldn’t be more proud of our AC Committee and the Lean community.”

That’s what Lean is all about—progress, not perfection. And this year’s conference proved again that when people come together with purpose, practice, and heart, incredible things happen.

Thank You

To our attendees, sponsors, presenters, volunteers, and the entire MLC Board and planning committee—thank you for showing up, leaning in, and building on the legacy of Lean.

Looking Ahead: 2026 Annual Conference

We're already planning for next year—and you can be part of it!
Secure your spot at the 2026 MLC Annual Conference with Early Bird Pricing available through January 31, 2026:

️ Member Early Bird – $460.00
️ Non-Member Early Bird – $590.00 (includes 1-year Individual Membership!)

VanDyk Mortgage Convention Center
️ August 4–7, 2026 | Muskegon, MI

Register Today!

Member Spotlight: Orchid Orthopedic Solutions

Fri, 11 Jul 2025 15:18:04 GMT

Orchid Orthopedic Solutions, a global leader in contract manufacturing for the orthopedic market, exemplifies how Lean principles can drive excellence in high-precision, highly regulated industries. Specializing in implants, instruments, and innovative technologies for joint replacements, spine, and trauma surgeries.

Recently, Orchid Orthopedic Solutions joined the Michigan Lean Consortium (MLC) as a Huron Member, formalizing a longstanding relationship with the Lean community in Michigan. While several team members had previously held individual memberships, the decision to become an organizational member was driven by a shared vision: Lean is for everyone.

That vision is championed by Holy Plaga, Operational Excellence Global Leader, who has been involved with the MLC since 2010. Over the years, she has served in a variety of roles, including Chair of the Board of Directors, and has consistently championed the organization.

Orchid’s organizational membership has helped expand access to Lean resources across its global footprint. In addition to U.S.-based participants, the company has team members from around the world engaged with the MLC, including a colleague in Sheffield, England, who actively participates in online programming. This reach demonstrates the power of MLC’s virtual offerings to connect Lean thinkers across borders and time zones.

Since joining as an organizational member, Orchid has taken full advantage of the MLC’s diverse offerings:

✅ Affordable, high-impact professional development
✅ Cross-industry collaboration and idea exchange
✅ Access to Lean tools and thought leadership
✅ Volunteer opportunities for team members in roles that may not traditionally offer them

Team members have already begun collaborating with other MLC member organizations, sparking new ideas and meaningful improvements. Gaining outside perspectives and unfiltered feedback has helped reinforce a culture of learning, experimentation, and shared purpose.

As Orchid continues to build and sustain its Lean culture, the MLC is proud to be a trusted partner.

With a strong emphasis on people, collaboration, and continuous improvement, Orchid exemplifies what it means to lead Lean from within, whether that’s in Michigan, across the U.S., or around the world.

As Pascal Dennis said, “Intensity is the soul of lean production, and team members are its heart.” At Orchid, that belief lives in every improvement effort, every collaboration, and every voice.

Here’s to the next chapter of continuous improvement, powered by people.

MLC Welcomes New Board Leadership and Directors

Fri, 18 Apr 2025 11:13:46 GMT

MLC Welcomes New Board Leadership and Directors
Exciting Transitions Usher in Fresh Energy for 2025 and Beyond

The Michigan Lean Consortium is excited to announce several recent changes to its Board of Directors. These transitions mark a new chapter of leadership, growth, and collaboration as MLC continues to champion Lean thinking across Michigan’s diverse sectors.

New Leadership at the Helm

After years of dedicated service, Holly Plaga has stepped down as Board Chair. We thank Holly for her outstanding contributions and leadership. Stepping into the role is Pamela Burgess, a seasoned professional with a deep commitment to continuous improvement. Pamela has served MLC in various capacities—including Board Secretary and Event Director—and brings extensive experience from her role in Michigan’s Department of Technology, Management and Budget.

Pamela is joined by Josh Smith, who has moved into the Vice Chair position while also serving as Community Director. Josh previously led MLC’s training initiatives and brings his signature energy and passion for Lean community-building to this expanded leadership role.

Welcoming New and Transitioning Directors

We are thrilled to welcome three new directors to the board:

Michelle Formanczyk joins as MLC’s first-ever Outreach Director. This new role reflects MLC’s growing commitment to statewide collaboration and expanded partnerships. With over 25 years of experience in learning and development, Michelle brings innovative thinking and a talent for connection-building.

Kim Ziegler steps into the role of Membership Director. An active MLC member since 2013, Kim is a leader in Operational Excellence at Dart Container Corporation and brings deep expertise in strategic improvement and member engagement.

Chenoa Reyes has accepted the role of Secretary. A Process Improvement Specialist with the State of Michigan, Chenoa is a Lean-certified professional with a passion for making systems more effective and efficient.

In addition to our new board members, we celebrate the evolving roles of current directors:

Stephanie Welch transitions into the role of Training Director, bringing over 15 years of experience in pharmaceutical operations and a passion for teaching continuous improvement principles.

Melissa Sherman will now serve as Events Director, leveraging her experience in utility and higher education sectors with a focus on leading change and cultivating Lean learning opportunities.

Robert Sturza, a long-time Lean advocate, healthcare professional, and MLC Board Member, has assumed the role of Program Director, expanding his impact on MLC’s content and strategic programming.

Dr. Patricia Malone continues in her role as Treasurer, bringing deep financial and strategic expertise as a CPA. She supports MLC’s mission with a strong focus on purposeful, sustainable change.

Looking Ahead

Each board member brings unique skills and perspectives, united by a shared commitment to advancing Lean principles throughout Michigan. The Michigan Lean Consortium is excited to continue building momentum in 2025 with this dynamic leadership team.

We are grateful to all our past and present board members for their service—and to our community for continuing to support our mission. With this new team in place, we are more equipped than ever to drive meaningful, measurable change.

You can learn more about the full Board of Directors and connect with them by visiting our Board of Directors page—we welcome your questions, ideas, and collaboration.

MLC Member Spotlight: Consumers Energy

Fri, 21 Mar 2025 16:05:43 GMT

Member Spotlight: Consumers Energy

For nearly a decade, Consumers Energy has stood out not only as one of Michigan’s most trusted utilities but also as a committed leader in Lean thinking and continuous improvement. As a Superior Member of the Michigan Lean Consortium (MLC) since 2017, Consumers has continuously invested in Lean principles to enhance operations, elevate customer experiences, and drive innovation across the organization.

Consumers Energy is an investor-owned utility (IOU) that delivers natural gas and electricity to residential, commercial, and industrial customers throughout Michigan. With a mission to provide safe, reliable, and sustainable energy, the company utilizes a balanced portfolio of generation sources—including natural gas, hydroelectric power, solar, wind, pumped storage, and renewable natural gas (RNG). That balanced approach mirrors Lean principles: intentional, efficient, and adaptable to change.

At the core of their internal Lean efforts is the Lean Center of Excellence, where professionals like Sr. Quality Improvement Consultant Melissa Sherman guide process improvement initiatives across departments. Melissa plays a key role in embedding Lean principles into everyday operations, ensuring they’re more than just a set of tools—they’re a part of the company culture.

But Consumers Energy’s commitment to Lean extends beyond its internal walls. Since joining the MLC, the organization has actively contributed to the Lean community. They’ve engaged in events across the state, including volunteering at the 2022 Annual Conference, and further deepened their involvement when Melissa joined the MLC Board of Directors in late 2022, serving in both Events and Secretary roles.

So why does Consumers Energy remain a committed member of the MLC? The answer is simple: value.

From virtual coffees and Gemba walks to one-day summits and the Annual Conference, MLC provides countless opportunities for Lean professionals to learn, grow, and connect. The chance to “go-see” how Lean is applied in other sectors, hear from diverse voices, and bring back new ideas is invaluable to their team.

“Through my involvement with the MLC, I have built a valuable network of colleagues, deepened my knowledge and passion for Lean principles, and experienced significant personal and professional growth,”- Melissa Sherman.

As Consumers Energy continues to lead in both the energy and Lean spaces, the MLC is proud to count them among its most active and engaged members. Their passion for improvement, innovation, and community makes them a model for what Lean leadership looks like in action.

Here’s to many more years of partnership, progress, and purposeful problem-solving.

MLC Member Spotlight: Sebright Products, Inc.

Fri, 07 Feb 2025 18:12:32 GMT

For over four decades, Sebright Products, Inc. has been a leader in designing and manufacturing waste handling and recycling equipment. Founded in 1978 and incorporated in 1984 by Brent Sebright and Lee Murray, the company has built a reputation for engineering excellence, reliability, and sustainability. Based in Hopkins, Michigan, Sebright Products continues to innovate, producing rugged, high-quality equipment that meets the evolving needs of industries worldwide.

Beyond manufacturing, Sebright takes pride in offering turnkey installations and exceptional after-sales service, ensuring their customers receive long-term value from their investments. Their solutions impact businesses, municipalities, and global corporations, driving efficiency, sustainability, and better waste management practices.

Sebright & the Michigan Lean Consortium

Sebright’s journey with Lean and the MLC began in 2022 with just two members. After attending the Grand Rapids Lean Summit in 2024, interest in Lean thinking skyrocketed across the company. By May 2024, ten Sebright employees had become MLC members, actively engaging in Lean learning and professional development.

“We’ve started our Lean journey and recognize the value of the Michigan Lean Consortium,” says Emir, a key leader at Sebright. “The events and resources offered by the MLC provide our team with opportunities to connect with other companies and learn Lean practices and tools.”

This commitment is evident—six Sebright Products team members are currently enrolled in the MLC Green Belt Course, reinforcing their dedication to continuous improvement and operational excellence.

Meet Emir: Leading Sebright’s Lean Transformation

As a key executive at Sebright, Emir plays a pivotal role in shaping the company’s future. His responsibilities include:

✅ Developing and executing Sebright’s strategic vision

✅ Overseeing executive teams and company culture

✅ Budgeting, forecasting, and tracking company performance

✅ Driving innovation and operational excellence

Emir first discovered the MLC five years ago through another member after visiting the City of Grand Rapids Inventory Facility. After volunteering and attending conferences, he deepened his involvement and joined the MLC Board in August 2023.

His leadership philosophy?

"Your personal growth and success depend on your ability to deal with people."

Why Sebright Chooses MLC

Sebright Products is committed to embracing Lean principles as they continue their improvement journey. Their MLC membership gives them access to:

A powerful network of Lean professionals and industry leaders

Hands-on training and events that drive real-world improvements

Continuous learning opportunities to strengthen their Lean capabilities

Sebright is proof that Lean is not just a methodology—it’s a culture shift. By investing in Lean training and embedding continuous improvement into their daily operations, they are positioning themselves for long-term success.

We are thrilled to have Sebright Products as an active part of the MLC community and look forward to their continued Lean journey!

MLC Member Spotlight: Dematic’s Victory at the 2024 Lean Excellence Competition

Tue, 22 Oct 2024 16:14:35 GMT

The Michigan Lean Consortium (MLC) was thrilled to partner with the 2024 Lean Solutions Summit, which brought together Lean professionals from across industries. A standout feature of the summit was the Lean Excellence Competition, where teams of six individuals competed in a live Kaizen-type event, transforming poorly performing processes into models of efficiency and success. MLC is proud to spotlight one of our Superior Level members, Dematic, who won this exciting competition.

At the summit, teams tackled challenges such as poor quality, machine downtime, and inventory management. Armed with Lean tools and methodologies, Dematic and other competitors worked against the clock to unravel inefficiencies and implement ingenious solutions. This high-pressure event tested the teams’ technical expertise, collaboration, innovation, and Lean leadership.

The Dematic team—comprising Kelly Robson, Tonna Agim, Kim Egan, Paul Hoekwater, Kyle Mahoney, and Brian Bolen—stood out for their ability to quickly assess the situation, devise creative solutions, and work seamlessly as a unit. Their performance exemplified Lean principles such as waste reduction, continuous improvement, and respect for people.

Brian Bolen shared his excitement about the competition, saying, "Despite the challenges of working with a team of full-time facilitators, I was really impressed with our team’s ability to work together, show our thinking, and produce championship-level results. It was a great day working with the team. Thanks to John Dyer, the Lean Solutions Team, and the other facilitators for creating such a rich environment for learning and improvement."

For Kelly Robson, the competition wasn’t just about winning but about the growth and experience gained: "We appreciate the opportunity provided by the Lean Solutions Team, John Dyer, and all of the judges. This was a wonderful team-building experience for Dematic, and we look forward to having others from our organization compete at future events!"

The Lean Excellence Competition fostered a spirit of innovation and demonstrated the power of Lean principles in action. Teams like Dematic exemplified what it means to continuously improve and innovate under pressure. Their success highlights the value of Lean methodologies in transforming not just processes but entire organizations.

Congratulations to Dematic for their impressive win, and we look forward to seeing more outstanding achievements from them in the future!

2024 Distinguished Service Award Winner

Fri, 06 Sep 2024 12:46:23 GMT

CONGRATULATIONS to our 2024 Distinguished Service Award Winner: State of Michigan Office of Continuous Improvement!

Thank you from the bottom of our hearts for your continued service and support of the MLC!

Holly Grandy-Miller
Jim Willems
Pam Kenney
Andrew Halfman
Pamela Burgess
Stacie Noel
Joel Feldpausch
Christopher Fizzell
Hannah Barton

Celebrating Success at the 2024 Annual Conference!

Fri, 16 Aug 2024 12:52:12 GMT

An Amazing Event!

"What does it take to plan the worlds best Lean conference (IMO)? Some stats: 11 months of planning; 20 planning meetings; 500+ people-hours of prep, action items, speaker wranglin'... then 4 days of the actual thing!" - Dave Kippen

Thank you to our events team, attendees, and sponsors for making this year's event a success like we've never had before!

Check It Off The List!

✅ 4 days of amazing learning and networking

✅12 Breakout Sessions

✅Panel of Lean Experts

✅Networking — Network and bond with other learners, make connections

✅Gemba Walks — “Go see” what is happening at some great spaces

THANK YOU TO OUR PRESENTERS

Amy Gowder, President and Chief Executive Officer, GE Aerospace Defense & Systems
David McRaney, Science Journalist + creator of blog, book, and podcast “You Are Not So Smart”
Joshua Smith, Internal Training & Education Lead @ ZFS TECHNOLOGIES
Jeff Zupancic, Lean Consultant/Facilitator @ Lean Learning Center
Bill Artzberger, LSSBB, PMP, Partner, Lean Learning Center
Kaleb Foss, MBA, Manager Continuous Improvement @ Munson Healthcare
Brian DeVries, Director, Global Business Improvement Leader | Executive Coach | Operational Excellence through Operational Experience
Brian Johnson, Training Specialist III @ Grand River Aseptic Manufacturing
Enda McGonigle ACMA, CGMA, System Director Supply Chain @ Munson Healthcare
Tracy Cleveland, Vice President Supply Chain @ Munson Healthcare
Brian Calkins, Manager, Continuous Improvement, Americas-Solutions Development, Lean Six Sigma Green Belt @ Dematic
Lindsay Dewey, Sr. Continuous Improvement Specialist @ Munson Healthcare
Penny Cox, Sr. Continuous Improvement Specialist @ Munson Healthcare
Emily Miner, Continuous Improvement Specialist @ Grand River Aseptic
Lucas Apol, Continuous Improvement Specialist @ Grand River Aseptic
Michael Goodrich, Senior Supplier Quality Engineer @ Consumers Energy
Jody Tupper, Principal Supplier Quality Engineer @ Consumers Energy
Mark Graban, Consultant, Author (“The Mistakes That Make Us"), Speaker, Coach, Podcaster, Senior Advisor to KaiNexus
Lisa Eshbach, PhD, Professor, College of Business, Ferris State University
Dennis Wade, Director, Pawley Lean Institute, Adjunct Professor, Oakland University
Toni Racco Benner, Chief Difference Maker, Racco & Associates Inc.
Kennith Scott, HeartMath Inc. Certified; NeuroChangeSolutions Consultant
Jessica Merwin, Owner, New Moon Yoga LLC
And our amazing emcee Debra Levantrosser!
Our Lean Communicators Pavilion Sponsor and Live Podcast HostPatrick Adams interviewing keynote speaker David McRaney

Mark Your Calendars for 2025!

Tuesday, August 12, 2025, 5:00 PM – Friday, August 15, 2025, 12:00 PM @ Bavarian Inn & Lodge, Frankenmuth, MI

Celebrating Success at the GR Lean Summit: Less Is More

Mon, 18 Mar 2024 15:16:24 GMT

The GR Lean Summit was a resounding success, with every seat filled, showcasing the growing interest and commitment to Lean practices in today's business landscape.

Thank you so much to our sponsors: GVSU College of Engineering and The Small Business Association of Michigan! Here's a glimpse into the highlights and key takeaways from this inspiring event:

Full House! 100% Registration: The enthusiasm of the attendees was great as every ticket was spoken for, reflecting a strong dedication to learning and implementing sustainable Lean principles.

Essentiality of Lean Practices: Brian Calley, President of the Small Business Association of Michigan, underscored the critical role of Lean practices in navigating challenges such as workforce shortages, tight margins, and economic uncertainties. His insights shed light on why Lean methodologies are indispensable for businesses aiming to thrive in today's dynamic environment.

Avoiding the Lean Appearance Trap: Patrick Adams, CEO + Executive Lean Coach at Lean Solutions, emphasized the importance of prioritizing continuous improvement over busywork and unproductive meetings. His message resonated with the audience, urging them to make Lean practices a non-negotiable part of their business strategy.

Building an Army of Problem Solvers: Beth Crowley, Vice President Operations, Crowley Group, shared valuable insights on the importance of cultivating a workforce of skilled problem solvers. By empowering individuals with the tools and mindset to tackle challenges head-on, organizations can foster resilience and drive sustainable improvements across all facets of operations.

Improve Less: Chad Bareither led a breakout session emphasizing the balance between agility and stability in Lean initiatives. By focusing efforts on a select few areas for improvement and fostering collective commitment, businesses can achieve higher success rates and sustainable progress over time.

Swift Style: Dave Kippen was Taylor-made to Emcee! Thank you so much to Dave Kippen, Continuous Improvement (CI) Manager, ADM, for hosting the Lean Summit! His humor and energy had everyone amped up for their Lean learning era!

Customer Service Commitment: Attendees toured the Alro Steel Metals Service Center providing an opportunity to review plant changes and investments made in the past couple years to improve productivity, safety, and customer service. The Metals Service Center was founded in 1948 by Al Glick. Participants learned of the history of the one Garage and one truck in Jackson, MI that, with Al’s hard work, dedication, and commitment to customer service, have expanded to over 80 locations in 16 states.

The GR Lean Summit not only provided attendees with actionable strategies and insights but also served as a platform for fostering collaboration, sharing best practices, and inspiring transformative change. As we reflect on the event, we extend our gratitude to all the speakers, participants, volunteers, and sponsors for their contributions to making this summit a resounding success.

Let's continue to embrace Lean principles, drive innovation, and cultivate a culture of continuous improvement in our organizations and beyond. Together, we can navigate challenges, seize opportunities, and chart a path towards sustainable growth and success. Here's to a future fueled by Lean sustainable thinking and collective dedication to continuous improvement!

Systems Thinking for Lean Practitioners

Fri, 01 Dec 2023 18:17:59 GMT

By: Christina Dragonetti, Development and Communications Manager, The W. Edwards Deming Institute

“I am not here to teach you anything new, I’m here to make you see things that you would not normally see.” – W. Edwards Deming

From an early age, we learn to break things into parts. We learn the ABCs linearly: A to B to C to D. We learn to break math problems into pieces to solve them. Later, we're taught to compartmentalize entire subjects. History is different from literature, which is different from science, and so on.

No wonder we approach business by breaking departments or projects into parts and trying to optimize each separately!

But even with tools like Lean, some problems get solved…and then come back. That’s what Dr. Deming called a “system problem.” Breaking the problem into pieces and solving each, then putting it back together, doesn't always work. You are analyzing each part as though other parts aren’t involved with the problem. When you step back and look at the interaction of the parts with each other and with the people, processes, and systems around them, you will more readily see why the problem continues. Plus, you'll see how and where to intervene for a permanent solution.

For example, in a physical therapy clinic, they had problems with patients missing appointments. If you think of this as a problem with patients, your receptionists repeatedly call and email them about making and keeping appointments. Each appointment is scheduled individually. This sometimes impacts treatment schedules and causes patient confusion. Also, the hours spent on these calls and emails take time and focus away from the aim of the organization: helping clients reach their highest physical potential.

Using systems thinking, you see this as a problem with the entire appointment-making process.

In this real-life example, everyone wanted to focus on the aim of supporting patients, not on the chaotic scheduling process. With the support of management, the receptionists across 4 offices devised a plan using Plan-Do-Study-Act. They decided to schedule all the recommended appointments for each patient based on their treatment plan when they come in the first time. This plan eliminated the many calls and emails required to schedule appointments. The result? Patients mostly stopped missing appointments. They got the therapy they needed at the proper intervals. Staff and therapists were better able to focus on helping patients reach their goals.

What are the key attributes of system thinking?

Systems thinking requires looking at your organization in a new, integrated way. Every system must have an aim: the reason the system exists. Your aim must include the future and the value your organization creates for the world.

For example, at The Deming Institute, our aim is: “enriching society through the Deming philosophy.” Everything we do, including our learning events, how we communicate, and our administrative processes, are working toward sharing this knowledge with the world. (Note: "making money" is not an aim; it is a byproduct of your system.)

Once you’ve figured out the aim of your organization, identify inputs, processes, and outputs (positive and negative) of the system, as well as the customers for each. Customers can be internal or external to the organization. At the organization level, inputs can include staff members, government regulations, technology, and the suppliers who provide inputs. Some organizations include COVID or global warming as part of their inputs. Processes include anything that adds value to your product or service or keeps the organization running.

For example, in an ice cream business, processes include creating new flavors, billing methods, payment processing, manufacturing, distribution, sales, and all the people involved in all those processes. The interaction of all these parts and people, working toward a common aim, creates a system.

Finally, identify your outputs. These can be good: profit, brand recognition, happy customers, happy employees, influence on legislation, reduced carbon footprint, and more. Outputs can also be negative: waste, legal action, insolvency, unhappy vocal customers, or staff turnover. For some organizations, your output also includes the success of the clients using your product or service. When you create this level of detail about the interacting components of your system, you can begin to draw a picture of the components that you have to manage towards the aim.

This “big picture” view of your organization calms the chaos, (mostly) prevents firefighting, and helps everyone understand their place – and therefore their value – in the organization.

Why use systems thinking?

Systems thinking, as Dr. Deming described it, is helpful for tasks, processes, organizations, families, communities, society, and ourselves. It allows for a more rational and methodical approach to problems. Everyone in the organization works toward a common aim. Happy customers, high morale, low turnover, profit, and innovation are byproducts (outputs) of a well-designed system.

If you want to learn more about the Deming Management Methods or his 14 Points for Management, visit www.deming.org. To learn more about our online learning program Deming NEXT visit deming.org/demingnext.

TAKT TIME 101: We Got The Beat Recap

Fri, 20 Oct 2023 15:21:26 GMT

The MLC hosted an online Coffee Chat with Beth Crowley Presenting Takt Time 101

Takt time is how often a product must be completed to meet customer demand. Cycle time is how long it takes to complete work. Beth used the image below to show us an example and asked the question, will this process deliver on-time?

Takeaways

Unbalanced lines, over production, and of course the Takt time examples
Takt time depends on high production of standard products in a repeatable process. It's not great for customized orders, job shops
World War II Bomber production at Willow Run highlighted that Ford's Sorenson used the concept of Takt time and process cycle time to redefine how a Bomber could be built each hour

The MLC is grateful to Beth Crowley and to all those who attended. It's great to see what's working and not working on Lean journeys; we are all in this together.

We welcome more opportunities for member learning and sharing. Email events@michiganlean.org to discuss how you can partner with the MLC on Gemba Tours and more.

Gemba Walk Recap—Granger Construction

Fri, 15 Sep 2023 15:17:37 GMT

Granger hosted MLC learners on Friday 10/13/23, the group was introduced to the Granger construction team at the Ford Motor National Product Development Center a 92,000 sq. ft. reconstruction project in Allen Park, MI.

The tour included a summary of the project by Joann Kobacki, Project Manager and Chris Scharlach Lean Operations, and others on the team.

Below are a few highlights of what was learned.

Lean construction is as valuable as Lean used in other environments; consider flow, pull, and waste.
Joann reviewed how flow of work coordinates elements of moving through a project by staging areas of focus. She illustrated how entire floors and areas are mapped to create flow.
Chris has been at this with Granger since 2015 and explained successes like learning to use LCI (Lean Construction Institutes) contributions for software such as Last Planner has been a big lift to organize the flow of project materials and people.

The Granger team was gracious in offering lunch to the 20 plus MLC attendees and a working discussion followed.

The MLC is grateful to Granger and to all those who attended. It's great to see what's working and not working on Lean journeys; we are all in this together.

We welcome more opportunities for member learning and sharing. Email events@michiganlean.org to discuss how you can partner with the MLC on Gemba Tours and more.

Gemba Walk Recap—Cummins Sales and Service

Fri, 16 Jun 2023 13:36:00 GMT

Cummins Sales and Service is a leading provider of diesel-engine service for on-highway trucks, emergency vehicles, school buses, and more.

Participants took a tour the facility
Conducted a waste-walk
Saw the many 5S Improvements and use of Visual Management tools throughout the facility

The MLC was excited to participate in an amazing gemba walk at the Cummins Sales and Service station this month!

Thank you so much for the opportunity to learn!

From the Chair—June

Wed, 07 Jun 2023 13:30:45 GMT

Summer in Michigan is the best!

The 2023 Annual Conference is our major event of the year! Held in breathtaking Traverse City, MI this August, the offerings this year reflect feedback from attendees and membership throughout the year from all of our events. I am very excited to see everyone and learn what has been happening in your lean worlds!

During the conference the MLC Board of Directors holds its annual public meeting to share the journey over the past year and where we are headed. Our directors are volunteers who work very hard, year round to create direction and support the MLC. Although, election nominations have come to a close we are always looking for interested humans to join the team. If you are interested, please contact me directly!

Have a safe month and I hope to see you in August.

For the love of Lean,

Holly

From the Chair—May

Fri, 12 May 2023 15:10:47 GMT

As new life emerges around us, it’s a great time to reflect, set new goals, create plans, and take action!

In late April we said, “thank you” and “farewell” to our four University of Michigan students, who have graduated and moved on to begin their careers. Fiona, Grant, Markus and Keaton were of great assistance evolving our strategy mindset and deep diving to bolster areas of our organization!

We also completed our Q2 strategy meeting. After a year with this team and six months developing and executing a Purpose Map we had moved the improvement needle and have had many great lessons learned.

I am excited to move forward continuing to develop long-term strategy and develop actions, short term to achieve our new future state. We would not have been able to do this without the assistance of our four University of Michigan students!

We have migrated to MSOffice platform! You, as membership, should see enhanced communication and ease of connecting virtually for events. We as a board, have greatly improved our communication, have better organized historical documents, and are now working off the same platform. A huge “thank you” to Melissa Sherman for spearheading the procurement and transition of this project!

Keep in mind May is the Michigan Lean Consortium Board of Directors Election Month. During the month of May we solicit for interested members who are willing to join our team, by nomination. Those nominations are then vetted and then sent to the membership for a vote. Please watch for multiple announcements through May for nominations and in June for the opportunity for vote in new board members.

Annual Conference registration is also open!

The AC team is just part of the overall events team and I wanted to give a big shoutout to everyone supporting all the events! Our events have been outstanding, and the Annual Conference will be no different! As a staple, your feedback helps us directionally pinpoint what 2024 will look like. Please be sure to provide candid feedback whenever you are able.

Lastly, I want to thank all the volunteers who have been supporting the MLC. You are the fiber that makes this organization great!

Be safe and have a great month!

For the love of Lean, Holly

Subject Matter Expert of The Month—May

Fri, 12 May 2023 15:06:01 GMT

Jeff Varani was our April Coffee Chat Subject Matter Expert.

We were delighted to have Jeff Varani as our April Coffee Chat Subject Matter Expert. Jeff provided an insightful presentation on Root Cause Analysis (RCA) that gave us an overview of the tools and examples of how to apply them. He also shared the real-world outcomes and resolution of challenges. Jeff's expertise and experience in the field of RCA was invaluable and we are grateful for his contribution to our Coffee Chat.

Jeff Varani is the Service Growth Director for New Power Products at Cummins Sales & Service North America (CSSNA), a division of Cummins, Inc.

Before assuming this current role, Jeff was the General Manager for mid and northern Michigan service operations of CSSNA. Responsibilities included directing the day-to-day operations of shop and field service operations for engine and power generation markets, product sales, customer experience, health & safety, and creating the right environment for the team. His experience leading cross functional teams, and operating knowledge of other market locations helped turn around a key underperforming market.

Thank you, Jeff, for sharing your knowledge with the Michigan Lean Consortium!

From the Chair— April 2023

Tue, 11 Apr 2023 16:41:38 GMT

Happy Spring!

David Mann wrote in his book, Creating a Lean Culture, “20% of the effort in a successful lean transformation is using the tools, while 80% is changing the way leaders think and their management practices.”

The MLC was able to showcase both the physical and the mental aspects of Lean in the month of March! We featured an extremely impactful Lean Leadership Summit and a Gemba Walk at Sartorius and Zingermans Mail Order. Thank you, MLC Events team for organizing such great events. Also, a note that the 2023 Annual Conference registration is now open!

The board continues to meet monthly with directors running their respected areas of focus on a daily basis. We focus on the PDCA strategy at our quarterly face to face. What is thrilling to see is the strategy is beginning to work! We know this by registrations for events, feedback from events and an increase in membership. We had a huge spike in new members this month. Welcome, all who have joined the MLC! Please continue to provide your candid feedback to the board members.

The election process for the board of directors begins in May. If you are interested in running for a board seat, please keep an eye out for the announcement coming soon.

The MLC is great because of its members. Thank you to everyone who supports the MLC every day is their way.

Be safe and have a great month!

For the Love of Lean,

Holly Plaga
MLC Board Chair

Subject Matter Expert of The Month—Emir Avdic

Tue, 11 Apr 2023 16:35:18 GMT

Emir Avdic was our March Coffee Chat Subject Matter Expert.

March's MLC Lean Coffee Chat equipped participants with the language and knowledge needed to increase leadership buy-in for their Lean efforts and practices.

View: How to Deal with Non-Committed Leadership in our presentation library!

For the past two decades, Emir has focused on the development, management and execution of strategic business development programs across global markets. This includes management and coordination of globally based employees and resources to develop international expansion strategies, validate sales opportunities, identify, and vet strategic partners, guide clients through acquisitions/greenfield operations in international markets and execute international expansion strategies on behalf of our clients. He has worn many hats in many different industries in the past years.

In the previous years Emir has worked with small to medium sized companies but also multi-billion-dollar organizations looking to expand into Europe or the United States either through entity setup, acquisitions or greenfield operations as well as managing the businesses on behalf of his clients.

Thank you, Emir, for your time and expertise!

Subject Matter Expert of The Month—Sakeena Rashid

Tue, 11 Apr 2023 16:32:57 GMT

Sakeena Rashid was our February Coffee Chat Subject Matter Expert.

The month of February allowed us to expand our horizon and look at how to best present a Lean Résumé. Our Subject Matter Expert of the Month, Sakeena Rashid provided a thought-provoking presentation title, From Résumé to Recruited: How to get your foot in the door and move up the corporate ladder. The engaged audience had questions and Sakeena had the answers! Thank you so much for sharing your knowledge with the MLC.

If you missed the presentation, the recording is on our website for members.

Sakeena is a professional writer with over 20 years of experience writing content, blog posts, and articles for both online and print publications. Sakeena is a former Certified Advanced Résumé writer (CARW) and Certified Employment Interview Consultant (CEIC). She lives in Grand Rapids and spends her time working as a freelance writer and is pursuing a degree in software engineering.

Thank you, Sakeena, for sharing your knowledge with the Michigan Lean Consortium!

Student Spotlight— Fiona Boyle

Tue, 11 Apr 2023 16:28:19 GMT

Student Spotlight

Fiona Boyle is a senior at the University of Michigan studying Industrial and Operations Engineering with a minor in Entrepreneurship from Shaker Heights, Ohio. After graduation, Fiona will be working for United Airlines in Chicago, Illinois. Outside of school she enjoys cooking, traveling, and hiking.

Thank you to our University of Michigan Students for joining the team!

From the Chair—February 2023

Wed, 08 Feb 2023 18:15:01 GMT

I hope everyone’s new year is off to a great start! During the month of January, the MLC Board sat down and conducted the first quarterly meeting of the year at Orchid Orthopedic Solutions. The team at Orchid were gracious hosts and provided a wonderful tour of the Lansing campus. During the quarterly meeting the team reviewed their strategic plan and key performance actions to meet the strategic goals for 2023. Some goals were internal and other external, supporting all membership.

Key Performance Actions include:

Position the organization to be technologically proficient/efficient
Present ourselves professionally to all stakeholders (internal & external)
Understand individual skills sets and strengths of all volunteers, including Board of Directors
Increase awareness of the benefits and value of the MLC

The board measures the effectiveness of our over actions with registration threshold metrics. Supporting these threshold metrics are other input metrics. To date we are on track with our actions and continue to trek forward preparing for our second quarter.

Also, this month, we welcomed four seniors from the University of Michigan to our team. Fiona, Grant, Markus, and Keaton have chosen the MLC as part of their Senior Project. They are learning about strategy development and implementation; they are working with various offices to support our initiatives and will be attending our upcoming events. Keep your eye out for their biographies and attendance at MLC Events. We are so thankful to have them on the team!

Speaking of events, we have been extensively working to hold a Lean Leadership Summit in Q1. I am happy to announce March 24th we will have our first Lean Leadership Summit in East Lansing. Managers, if you are looking to develop your people, the Lean Leadership Summit will be an excellent addition to your employee’s performance objectives for 2023. An announcement will be out shortly with registration slated for mid-February.

Lastly, I want to thank all the volunteers who have been supporting the MLC. It is amazing the camaraderie and collaboration we have had revitalizing this organization.

Be safe and have a great month!

For the Love of Lean,
Holly Plaga, MLC Board Chair

Subject Matter Expert of The Month—Cheryl Underwood

Wed, 08 Feb 2023 18:13:06 GMT

Cheryl Underwood was our January Coffee Chat Subject Matter Expert. Cheryl presentation was titled, Save, Grow and Preserve Your Assets. She covered topics from picking a financial advisor, to understanding what a fiduciary advisor means, to reviewing credentials.

Cheryl also covered frequently asked questions and provided answers in between responding to participants inquiries. The survey results for this event were all fives (the highest possible score)!

Cheryl L. Underwood is an Executive Director – Investments at Oppenheimer & Co. Inc. (“Oppenheimer”). Cheryl has helped clients achieve their financial goals and aspirations for more than 20 years with her experience in retirement/pension plans and investments. She provides financial and investment advice helping clients to invest, grow, and preserve assets based on their individual needs and objectives. Her office is centrally based in East Lansing, Michigan.

Thank you, Cheryl, for sharing your knowledge with the Michigan Lean Consortium!

Student Spotlight—Grant Pinto!

Wed, 08 Feb 2023 18:10:41 GMT

My name is Grant Pinto, and I am currently a senior wrapping up a B.S. in Industrial and Operations Engineering Major. Originally, I am from the Philadelphia, Pennsylvania area. Professionally, I have experience working in the Healthcare and Tech Consulting industries but have been actively interested in promoting sustainability practices throughout my time at school. This interest led me to work with the MLC, and I am looking forward to contributing to waste reduction in the state of Michigan. In my free time, I enjoy staying active, specifically playing racquetball or tennis.

Thank you to our University of Michigan Students for joining the team!

From the Chair

Mon, 09 Jan 2023 15:53:15 GMT

Happy New Year! I hope this note finds you happy and healthy!

This month, my note to you is quite short as we are quickly approaching our Q1 Strategy Session and developing our offerings for 2023.

Speaking of development, keep the MLC in mind when working with your employees to create their development plan!

Can’t wait to share our strategy for 2023 next month!

For the Love of Lean,
Holly Plaga,
Michigan Lean Consortium Chair

Subject Matter Expert of the Month—Brittany Parks

Mon, 09 Jan 2023 15:51:02 GMT

Our Coffee Chat Subject Matter Expert of the Month was Brittany Parks.

Brittainy Parks provided a fun and useful presentation on Lean Tips to Survive the Holiday Season. She used a common appetizer (ham rolls) to discussed one-piece flow. She also covered how to implement 5S to your holidays, and other lean tools.

Brittany is the owner of Brittany Parks Process Consulting (BPPC). She is a competent, degreed, and certified Lean Six Sigma professional motivated by an enthusiastic desire to contribute to the continuous improvement and efficiency of business processes and systems.

Thank you, Brittainy, for your wonderful presentation.

Thank you for sharing your knowledge with the Coffee Chat participants!

From the Chair

Mon, 05 Dec 2022 15:47:48 GMT

Happy December! I hope this note find you happy and healthy!

Although life seems to be so hectic this time a year, this is also time to reflect and plan for 2023. Our board is following this process by creating our 2023 Strategic A3. We are now moving to the right side of the A3; future state creation! We are providing our hypothesis and determining key actions for improvement. I love this process and how it truly creates better communication, collaboration, and alignment! Developing a strategy is a long process and the team is committed!

I’d like to welcome Melissa Sherman to the board of directors. Melissa is overseeing members who are interested in volunteering to support the MLC. Volunteering has many variations. If you are interested in volunteering, please reach out to Melissa.

Last month we also had our 5th Annual Grand Rapids Summit which even Mother Nature could not stop! The first major snow of the year reminded us of the excitement, patience and understanding need to live in the beautiful and dynamic state. Even with the snow we had an incredible showing and representation of industry at the event. By your feedback on the surveys our active learning sessions were of high value, and you were able to walk away new knowledge. Please keep the suggestions for other active learning sessions coming so when designing medium to large conferences we can continue to meet your needs. Lastly, a huge MLC “Thank you” again to Dr. Wael Mokhtar and Grand Valley University for hosting the event.

Next month, don't miss the Coffee Chat on Dec. 16th! Future offerings are currently being developed including gemba walks! As you build your or your staffs 2023 development plans keep us in mind as a resource to provide great Lean content. We are working on a Lean Leadership event and a Lean Tools School for 2023 Q1 and Q2.

Please reach out with any questions or suggestions about MLC offerings to either Jayne Overbeck, Events Team Director or myself for more information.

I wish you all a peaceful and safe holiday season.

For the Love of Lean,

Holly Plaga,

Michigan Lean Consortium Chair

Subject Matter Expert of the Month—Kevin Olds

Mon, 05 Dec 2022 15:45:48 GMT

Our Coffee Chat Subject Matter Expert of the Month was Kevin Olds.

Kevin Olds provided an excellent presentation on Gemba Walks for November’s Coffee Chat. He discussed ways to ensure you and your company are optimizing your Gemba walks. He gave the group the important reminder of the Gemba basics: go see, ask questions, and show respect. Kevin works at the Michigan Manufacturing Technology Center (MMTC) in Traverse City as a Senior Business Advisor. He is enthusiastic about sharing is knowledge of continuous improvement with others and is a certified Lean Champion instructor.

He has facilitated numerous Lean and Six Sigma projects for his Northern Michigan clients. He currently serves on the Board of Directors for the Grand Traverse Area Manufacturing Council and hosts benchmarking events with the Lean Learning Consortium.

Thank you for sharing your knowledge with the Coffee Chat participants!

From the Chair

Tue, 01 Nov 2022 14:42:43 GMT

Hello Michigan Lean Consortium Practitioners,

Happy November! As we approach the holiday season we are continuing to reflect and plan for 2023. As mentioned in the last months newsletter, the board of directors has begun the strategic planning cycle and continues to follow the PLAN, DO, CHECK, ADJUST process to ensure we are headed in a beneficial direction for our organization. Our strategy will be shared in December on the internal website for all to review. Developing a strategy is a long process and the team is committed to following the process.

Our offerings continue to produce great learning and feedback from you. In October, I especially enjoyed the Negotiation Coffee Chat from Debra Levantrosser!

Next month is the Grand Rapids Summit. Thank you to those who have signed up to attend. I am honored to have the opportunity to present, How A Novice Can Facilitate Effective Strategic Planning. The strategic planning topic was brought forth by you, the membership, as a Lean tool you were looking to learn more about and take back to your organization.

Thank you and keep the recommendations coming! I am very excited to share and look forward to seeing your smiling face on November 18th!

Your feedback is always appreciated and thank you for your patronage and love for the MLC!

For the Love of Lean,

Holly Plaga,

Michigan Lean Consortium Chair

Subject Matter Expert of the Month—Debra Levantrosser

Tue, 01 Nov 2022 14:41:04 GMT

Our Coffee Chat Subject Matter Expert of the Month was Debra Levantrosser.

Debra Levantrosser provided a riveting presentation on Negotiation Tips and Tricks. Debra provided tips from negotiating salary and benefits to reducing speeding tickets!

She told the members to think about “What’s Most Important to You?” before entering discussions. Feedback on the event has been tremendously positive. Thank you, Debra for proving a brilliant presentation filled with superb content. Debra has over 30 years of executive level international leadership and management experience in many industries. She is currently a full-time faculty member at the University of Michigan (U of M) in the College of Engineering, Industrial and Operations Engineering department where she teaches Lean manufacturing, leadership for engineers, senior design, and coordinates career readiness workshops. Please join us for the next Coffee Chat on November 11th. Kevin Olds will be providing insights on how to boost Gemba Walks results.

Lean Tool Tip—Kimishibai

Tue, 01 Nov 2022 14:34:51 GMT

You improved your process and created new standard work now what? How do you help solidify the new culture? “Kamishibai”

by Bob Sturza, MLC Board Member

Kamishibai is a tool used as a visual control for performing audits within a process:

Uncomplicated tool for visual management.
Can be used on shop floors or office settings.
Natural extension of gemba walks.
Focus is on process management and control.
A simple, visual check card system used to review critical items within any work area.

Auditors carry out 1 to 3 audits daily.
Each process will have an audit card detailing the check to be made.
Audit cards are held in a box below the control board.
One side of the card is green stating the audit passed.
The other is red for failed audits and has countermeasures listed.
The card remains red until the countermeasure is applied and the cause is corrected.

Summary

Can you use this?
What processes would benefit from this kind of audit?

From the Chair

Mon, 03 Oct 2022 14:32:41 GMT

Hello Michigan Lean Consortium Practitioners,

I hope this note finds everyone loving our beautiful colors and weather this fall.

To start off I want to welcome our new corporate members from Tube Fab/Roman Engineering located in Afton, Michigan to the team! Also, Last month I am excited to share we were able to fill the last seat on the MLC Board of Directors by appointing Melissa Sherman of Consumers Energy to the board. Many of you may know Melissa through her extensive work with the Annual Conference. Her Lean systems and virtual tools knowledge will benefit the MLC as we move into 2023.

Welcome Melissa!

Thank you again to everyone who showed interest in running for a board seat! The last day of September the board held its Quarterly Strategy meeting where, with the help of two cycles of 90-day Strategic A3’s, we began to develop What the MLC is, Why we are here and Where we want to go. This session was super exciting as we now have our legs under us and can move forward with more stability and confidence. I will share more next month once we solidify our plan.

Lastly, through your feedback we are closing out 2022 with several events. We continue with Coffee Chats and Book Club which have been strong and well attended. I also wanted to remind everyone of the Grand Rapids Summit quickly approaching in Mid-November on the campus of Grand Valley State University and hope everyone registers and plans to attend.

Your feedback is always appreciated and thank you for your patronage and love for the MLC!

For the Love of Lean,

Holly Plaga,

Michigan Lean Consortium Chair

Benefit of the MLC Membership

Mon, 03 Oct 2022 14:30:52 GMT

Networking is just one of the benefits of the MLC membership. The MLC Book Club and the Annual Conference created opportunities to meet and build new friendships. Jayne Overbeck recently took a vacation to the Upper Peninsula and had the pleasure of spending time with Ruth Archer in Houghton, Michigan, and their alma mater Michigan Tech University (also Ruth’s workplace).

Please share your stories and pictures!

Subject Matter Expert of the Month—Brian Braman

Mon, 03 Oct 2022 14:26:40 GMT

Our Coffee Chat Subject Matter Expert of the Month was Brian Braman.

He presented on Problem Solving A3s. He discussed how he got people involved, what format they used (they get to choose!), and how to inspire and coach. There were numerous questions and wonderful insights in this interactive Coffee Chat.

Thank you again Brian! Brian’s background:

BSE in Industrial and Operations Engineering – University of Michigan
MBA – Western Michigan University
30 Years of experience in automotive industry
Transformation of steering column plant featured in the book “Becoming Lean”
1 Year lean manufacturing internship at Akebono in Elizabethtown, KY
Led consolidation of three plants to two with complete process transformation at Nexteer
10 Years of new program launch experience while supporting global operations (China, Mexico, Poland)

The next Coffee Chat is on October 21 st at 8:30 a.m. Please join us.

Communities of Practice Update

Mon, 03 Oct 2022 14:25:27 GMT

The 2022 Annual Conference held this August in Traverse City was memorable for a number of reasons, not least of which the end of Day 2 Ideation sessions.

Attendees broke into groups, and for about an hour at various stations- Communities of Practice (CoPs), Membership, and Events, we heard from our members, and non-members who attended. We asked how the MLC, and our various functions were serving, and not serving , our members. We listened, and took notes.

And from those notes and conversations we are fashioning the improvements members are needing from the MLC.

Communities of Practice will see a major update, designed to expand access to more members, create more diverse networks and discussions, and unlock the resources that are the members of the Michigan Lean Consortium.

Please bear with us as we work out the details. We plan to have it ready by year’s end, ushering in a new era of interaction for MLC members.

From the Chair—September Newsletter

Wed, 14 Sep 2022 19:14:14 GMT

Hello Michigan Lean Consortium Practitioners,

I hope this note finds everyone winding down their summer with great memories of the past few months.

The MLC also has enjoyed delivering value to you! Our Annual Conference had an amazing turnout and felt more like a reunion than a conference. I am so thankful to those volunteers who helped pull the AC together and you, the membership, for attending!

Traditionally during the annual conference we thank the former board members and introduce the new board members to the membership. This year we thanked and said goodbye to Vanita De Jesus, Josh Foster, and Kevin Olds. We introduced Jayne Overbeck and Alen Ganic. Pam Burgess was also reelected to the board for another three year term. Most recently, Debra Levantrosser, founder of the MLC, rejoined the board to support the membership office. Also during the annual conference the State of the Business was presented to the membership. Each director shared their portion of the Strategic A3 and their vision for the future.

At the end of September the board will hold the Q3 strategy meeting where we will be evaluating our 2022 work and begin designing 2023!

I hope everyone is excited to see the offerings the MLC will provide in the New Year!

Your feedback is always appreciated!

For the Love of Lean,
Holly Plaga,
Michigan Lean Consortium Chair

Subject Matter Expert of the Month—Megan Atkinson

Wed, 14 Sep 2022 19:11:47 GMT

Our Coffee Chat Subject Matter Expert of the Month was Megan Atkinson, CSM, CSPO, CAL. Megan presented on Visual Collaboration Tools for Remote Work and Learning. It was an interactive and informative presentation! Megan serves at the intersection of business and technology strategy as a Business Transformation Analyst at Dart Container.

She has spent over a decade dedicated to digital transformation through her work in experience design, product management, enterprise architecture, and process reengineering. Thank you again Megan!

September’s Coffee Chat subject is Problem Solving A3s presented by Brian Braman, Senior Manager, Operational Excellence at Orchid Orthopedic Solutions on September 16th.

Please let us know if you would like to present a topic!

2022 Distinguished Service Award Winners!

Wed, 14 Sep 2022 19:10:05 GMT

Each year at the Annual Conference, the MLC recognizes one or more individuals for their contributions to the organization. This recognition is called the Distinguished Service Award and it is awarded to a Dave Kippen and Debra Levantrosser.

Dave Kippen has been so integral to the success of MLC from his early days as a board member to his most recent contributions as Events Team Lead and Annual Conference Team Lead. Dave has been one of the largest supporters of MLC in its entire history. In fact, this is Dave’s second time being honored with this award. His first was in 2013. As Events Team Lead, Dave was the person responsible for coordinating and executing the full events calendar. During the shutdown periods of COVID, this was especially trying, and Dave always approached these situations with the MLC’s best interest as his priority. The MLC Board thanks Dave for his tireless efforts of volunteerism and are grateful for volunteers like Dave.

Debra Levantrosser was this year’s second awardee. Debra is the face of the MLC Annual Conference. For the entire history of the event, Debra has offered up her time and talents to be the Master of Ceremonies. She is a consummate professional, who always knows just the right activity to run or words to say during the event. She makes the Annual Conference fun and entertaining year after year and does it with grace. Debra was also a founding member of MLC and played a key role in laying the foundation of this important organization.

Please consider volunteering in any capacity where you feel you have talents that would help the MLC. This organization relies on volunteerism to continue to provide great resources and content to those around the state who are on their Lean journey.

Meet A New Board Member—Alen Ganic!

Fri, 08 Jul 2022 15:17:25 GMT

Alen Ganic, a former board member, is looking to expand our Government Community of Practice and support the board as needed. Alen will be formally onboarded in August at the Annual Conference and will be included in the MLC State of the Business on Thursday. We are very excited to have such a great team joining us as we move forward. Please Welcome Him To The Team!!

Alen Ganic
MANAGEMENT PROFESSIONAL | MANUFACTURING & PRODUCTION | LEAN SIX SIGMA

Alen Ganic is a dynamic and passionate leader and management professional with a track record of steering efficiency and continuous improvement by deploying Lean Six Sigma methodology and tools and leveraging team capabilities. He is recognized for the ability to transform businesses through training, coaching, and mentoring.

Twenty-plus years ago, Alen fell in love with the Lean philosophy. Since then, he has helped manufacturing plants with Lean transformation, coaching, and mentoring. Alen has also helped streamline and transform some departments and operations in the public sector.

In 2019 Alen received the Michigan Lean Consortium Distinguished Service Award for superb customer service and going above and beyond in time commitment and service to Michigan and the MLC community.

In his free time, he enjoys spending time with his family and reading. Also, he loves spending time outdoors, like kayaking, hiking, and biking. Alen speaks fluently three languages; English, Bosnian, and German.

Meet A New Board Member—Jayne Overbeck!

Thu, 07 Jul 2022 14:57:03 GMT

You may know Jayne Overbeck from being a part of the Events Team this year! She is new to the board and will bring fresh ideas along with strong project management experience to our team. Please Welcome Her To The Team!!

Jayne Overbeck
Senior Strategy Manager, Dart Container

Jayne Overbeck is a Senior Strategy Manager at Dart Container where she manages high-level program initiatives and helps to foster strong cross-functional collaboration. She is responsible for continuously improving the Strategy Department’s processes and methodologies to drive value and support better business outcomes. In addition, she leads kaizen events, teaches courses on Lean principles, and mentors team members.

Jayne started practicing Lean over 25 years ago. She attended the General Motors Quality Institute where she had the pleasure of meeting Dr. Deming. Her Lean journey received inspiration after observing the red bead experiment. Prior to joining Dart, Jayne gained project management, Lean and consulting experience working in multiple industries including manufacturing, healthcare, financial services, and technology. She has led continuous improvement projects in the US, Europe, and Asia.

Jayne has a bachelor's degree in Scientific and Technical Communications from Michigan Technological University. Jayne is an avid reader, she loves spending time her fur-baby Casey, and (of course) her wonderful husband Jim.

Lean Tool Tip! Visual Management Aids

Fri, 15 Oct 2021 13:52:47 GMT

Be sure to engage your graphics, marketing or other arts department early on in your Lean endeavors. There is a lot to do in Visual management, and their help will be invaluable.

In early Lean activities, 5S and area organization is key. As things progress, standard work is implemented, requiring visual representations to go with the narrative. Flow lanes, takt time, and a long list of others make your graphics team key to presenting the visuals in a timely and personalized manner.

If you don’t have a marketing or graphics department, there are several online tools that can provide examples of visually engaging representation of data, like Venngage or you can use online programs like Canva for visual management.

Get to Know a New Board Member! Joe Pesz!

Thu, 30 Sep 2021 13:54:49 GMT

Joe Pesz
Lean Coach/Consultant, JMPesz Design

I came to Lean in 2005, as a result of some problems my company was having with safety issues specifically related to gaps in our training. Learning and implementing 5S, Standard work and Value Streams mapping were my introduction, and those core tenets helped me transition over the last 16 years, from a Construction industry background into Manufacturing and Distribution, Supply Chain and most recently Healthcare.

Currently working as a Lean Coach/Consultant for my company JMPesz Design. Part time musician. Married with two kids, and five granddaughters.

Update from the Events Team by Dave Kippen, MLC Events Team Coordinator

Wed, 11 Aug 2021 20:32:23 GMT

Lean Tribe!

The Events Team took a big step forward this week and had a "re-introduciton" session for our Events Team volunteers. During Covid we pivoted to 100% virtual and did not need a lot of event support. There is just not as much work to do when an event is all online. Our eyes are on the future and the future holds IN PERSON EVENTS! (assuming Delta does not crash the party...).

Our re-introduction session reviewed the event planning process at a high level and what the different roles and responsibilities are for the different levels of volunteers. Long story short, our pool of volunteers are split into 3 main categories:

"Single day" event planners
"Multi day" event planners (conferences!!)
"Day Of" volunteers

We need a pool of each type to be able to execute all ranges and types of events for our membership. As always, if you are interested in being a volunteer, let me know!

Our events Master Schedule has a couple in-person events and in-person Coffee Chats on the list for the rest of 2021 (with a couple virtual events sprinkled in). Be on the lookout for updates and get yourself on the registration list!

Be safe,

Dave

MLC Membership––Did You Know?

Thu, 01 Jul 2021 23:38:37 GMT

Did you know that you have an MLC membership card?

If you need to access this card follow these steps:

Log into your account
Click on your name in the upper left hand corner

A page will be displayed that has your membership card and all the details about your MLC membership.

You will be able to update your information too.

Thank you for being a member!

Check Out the Membership Site!

2021 MLC Healthcare Symposium––Success!

Thu, 01 Jul 2021 23:34:53 GMT

The 9th annual MLC Healthcare Symposium was a success.

We had 100% attendance!

Here is some of the feedback we received:

❝I overall highly enjoyed the symposium. Hearing from Dr. Zarbo was fantastic, and the breakout session I attended with the Spectrum group was great to hear what they did, and how they did it❞

❝Dr Zarbo was fantastic❞

❝Dr. Sozener and Dr. Bassin were engaging and funny. I enjoyed learning about their Lean journey to a more productive and successful ER❞

Thank you to everyone that volunteered their time to help facilitate this event!

Congratulations for the winners of the 2021 Best in Healthcare Continuous Improvement Award!

We at MLC know there were so many Michiganders whose hard work and dedication led to putting Michigan on the frontline of the vaccine roll-out, and we recognized some of them for their contributions at our Virtual MLC Healthcare Symposium.

Read about the Winners!

Update from the Events Team by Dave Kippen, MLC Events Team Coordinator

Thu, 01 Jul 2021 23:29:34 GMT

You guys! We are beginning to plan in-person events for the fall of 2021!

This is such a big step toward getting the MLC “back to normal”. Over the years we have hung our hat on the amazing networking and relationship building opportunities that we have been able to offer in addition to Training and Education. As you well know, that has been a struggle when the world went fully virtual. Buckle up, we believe that is going to really change very quickly!

With that said, our ask for Event Team volunteers will be ramping back up. I have really struggled over the last 18 months trying to figure out how to use the volunteers who have already committed to helping the MLC Events Team. If you have felt left out, I apologize! Virtual events did not tend to need a lot of help. As we transition back to in-person, that will change. To our current resource team (and you know who you are!), expect to hear from me soon! If you are thinking of becoming a MLC Events volunteer, there are a couple of service categories we look at: Event Planner – This is someone who is willing to take an idea and run with it! We do have Event Planning Standard Work, so you would have some structure to follow. We give you the seed of an idea and you take it from there. Event Volunteer – This is for folks who are not interested in the extra work of planning, but love being on-site (brick and mortar or virtual) to do event kick-off, break out room lead, etc. Coffee Chat Planning Lead – This person would organize the Coffee events and work with Coffee Chat volunteers to execute them. These are all fantastic roles and are so fulfilling. You will meet the best people and be a part of changing lives.

If you are interested, please reach out to me and I will have a 1:1 discussion with you to see what you are passionate about and where we can use your talent! I cant wait for that first event where I get to see everyone’s smiley face IN PERSON!

Thanks,

Dave Kippen

MLC Events Team Coordinator

Volunteer for the MLC!

MLC ANNOUNCING RETURN OF IN PERSON COFFEE CHATS by Lauren Wisniewski, MLC Board Member

Tue, 29 Jun 2021 18:05:46 GMT

We miss you!

This past year has certainly been a long road for all of us and we are deeply grateful to our MLC membership community who stuck with us as we navigated virtual events. We also know that building a Lean network and learning through interaction are highly valued benefits of an MLC membership. Therefore, this summer, we are bringing back regularly scheduled coffee chats and we will look forward to holding these coffee chats in person as often as possible.

We will kick off the summer with a Lean Coffee Chat on July 16 at 9:00 a.m. in Ann Arbor (location to be determined), hosted by MLC Board Member, Lauren Wisniewski.

The MLC is committed to expanding our Lean networks throughout regional communities and we invite you to volunteer to host a Lean Coffee Chat in your area as well!

Please reach out to admin@michiganlean.org if you are interested in hosting a coffee chat.

We look forward to seeing you in person and having meaningful conversations that will inspire and brighten your day!

*Our priorities will be the safety and comfortability of our members as we seek out coffee chat locations. Per current guidelines, masks will not be required, but we encourage all who have underlying medical issues, those not yet vaccinated, and those who feel uncomfortable for any reason to continue to wear them.

Lauren Wisniewski

MLC Board Member

How can You Reduce the Cost of Training? By Becky Andree, MLC Board Member

Sat, 29 May 2021 02:19:21 GMT

One of the questions I get asked frequently by my clients…how can I reduce the cost of training? I have a few recommendations!

Leverage learning offered by organizations where you are a member. You are already paying a membership, so use the resources provided and often the organization has received a significantly discounted rate. MLC has great learning offerings with some exciting options coming up in the near future! Take a look at some upcoming workshops to see if they meet your needs!
Take a look at LinkedIn Learning. For $59.99/month, you gain access to a TON of learning offerings. I did a quick search on ‘lean’ which returned 791 results! If you are just starting your lean journey, 325 are beginner level! Intermediate had 259 results and Advanced had 37! If you pay for the year in advance, you get a 20% discount :)
Create a book group. Books are an inexpensive way to build knowledge and discussing in a group helps make the concepts come to life and how they might quickly be applied at your company! A few quick suggestions: Creating a Lean Culture by David Mann, The Flow System: The Evolution of Agile and Lean Thinking in an Age of Complexity by Nigel Thurlow, 2 Second Lean by Paul Akers.
Look at local college / university offerings. The MLC has partnerships with many Michigan academic institutions, in fact there is even a Community of Practice! Check with their local offerings or even get in touch with a MLC member of an academic institution to brainstorm ways they can support your organization's learning needs. Perhaps an intern that is a whiz at Lean in the classroom that could come in and help you make some quick wins?!

Training doesn’t have to be expensive. Get clear on what skills/capabilities you need, then get creative on how to build that capability. Need a little bit of extra help to get you started? I am always willing to spend 15 minutes discussing with MLC Members! You can schedule time with me on my OnceHub and select “Your Problem / 1 Solution.”

Becky Andree

MLC Board Member

CEO of Vertical Leadership Consulting

New MLC Mission Statement by Katie Labedz

Tue, 27 Apr 2021 14:47:16 GMT

The MLC has updated their mission statement to better fit their new board, member suggestions, and the changing times.

"Engage, connect, and develop people and processes in continuous improvement and Lean initiatives to positively impact Michigan."

Learn more about the MLC at our About Us page.

MLC Event Standardization by Dave Kippen, MLC Events Team Coordinator

Thu, 08 Apr 2021 15:42:43 GMT

The Events Committee is working on standardizing our offerings to help our membership know what to expect all throughout the year! Thanks to all who filled out the survey, that helped us shape our path forward. Here are a few things you can expect to see take shape very soon:

A repeatable “large event” cadence. We understand how important it is to be able to count on some of our favorite events happening at certain times of the year. The Annual Conference, the Healthcare Symposium, and the Grand Rapids Summit are the 3 major events that we plan on standardizing and offering at the same time each year.
A repeatable monthly events cadence. Our initial target will be one Gemba event, one Learning event and one Coffee Chat per month. This will help us curate content to fit those different events rather than relying on “whatever comes in” as ideas. Very proactive and thoughtful.
A focus on different levels of knowledge. We heard loud and clear that we have not made much of an effort to have events related to folks who are new or just beginning their Lean journey. We plan on fixing this! We plan on equally distributing events in 3 categories: Beginning, Intermediate, and Advanced levels of Lean. It will not be perfect, but a focus will be made to achieve a better balance.

These changes are very exciting and I hope all our membership will see value in these changes. Bringing knowledge and networking to Lean practitioners in Michigan is what we want to achieve through MLC events. I hope you join one or all of the upcoming amazing opportunities that we will offer!

Dave Kippen

MLC Events Team Coordinator

To learn more about MLC's events, visit the Events and Learning page!

Finding My Own Lean Path by Lauren Wisniewski, MLC Board Member

Wed, 07 Apr 2021 22:30:47 GMT

What I find so powerful and so valuable about Lean are the core concepts: seek to continuously improve and focus on respecting others throughout your improvement actions. These concepts are not business related strategies that apply in certain settings. They are human values that can be applied in any setting, work or otherwise.

My own path of coaching Lean within the nonprofit sector has allowed me to explore new territories while seeing just how universal Lean principles truly are. The majority of those with whom I have been in contact in the nonprofit sector are completely new to Lean or have only a vague understanding of what it means and how it applies. The continuously incredible part to me is how inherently aligned Lean thinking and nonprofit sector work can be. Nonprofits have empathy ingrained in their missions and a focus on serving others is what often brings nonprofit professionals to work everyday. Nonprofit professionals also often wear many hats, being the grant writer as well as the volunteer coordinator and on the marketing team, for example. So, being able to cut down on waste and streamline operations is critical to help nonprofits thrive. The core concepts of Lean often live in the heart of a nonprofit organization. It is just a matter of introducing the tools and formal methods through language and strategies that fit for the nonprofit environment.

I am fortunate to have learned Lean backwards. I saw the outcome of an incredible personal Lean transformation and used that inspiration to work my way backwards through books, practice, and finally, formal training. That backwards method showed me the powerful difference the Lean can make on a person’s everyday activities, relationships at work and with loved ones, impactful leadership, enjoyment and success at work, as well as the ability to solve any problem. There is an expansive array of Lean tools and resources to help reach a continuous Lean practice. The important point of these tools, however, reaches back to the core concepts. The tools are the how of the concepts, but what matters most is that those concepts are ingrained. In my work with nonprofit organizations, I am constantly thinking about and adjusting the Lean language around the tools in order to help those who I serve understand the core concepts.

Whether you are new to Lean or a well-seasoned expert, there is always more to discover, more to share, more learning to be inspired by. Sometimes even stopping to reflect upon what you have already learned may bring the greatest insight. Or perhaps shifting your mindset to be open to another new idea may make all the difference. Whatever it is, I hope you feel the welcoming and wonder of Lean as I do.

Lauren Wisniewski

MLC Board Member

President of Rise Consulting, Co.

Start or advance in your Lean journey with one of our training events!

MLC Organizational Changes by Katie Labedz, MLC Board Chair

Thu, 18 Mar 2021 16:06:53 GMT

We are excited to announce organizational changes to the Michigan Lean Consortium Board of Directors. Tony Hayes has decided to step down from the Chair position. We cannot thank Tony enough for all of his hard work and effort leading the Board this past year. He has been an outstanding leader and role model for MLC. We are proud to announce that Katie Labedz has accepted the role of the Chair position. Katie previously was responsible for strategy on the Board. Katie comes to the MLC with over 20 years of Lean experience and previous experience being on the Board of Directors for other non-profit organizations.

Vanita DeJesus has accepted the role of the Vice Chair position! We are excited to continue to work with Vanita in this new capacity as she continues to bring new and exciting ideas to the MLC! Mike Wiserma will end his term as Vice Chair in August 2021. Lauren Wisniewski will work with Vanita to be responsible for membership. We thank Lauren for her willingness to take on this new role.

We are also pleased to announce Josh Foster has accepted the role of the Treasurer position after Richard Love departed earlier this month. We thank Richard for his time and assistance on the Board. We are actively executing our transition plans and appreciate your continued support of the MLC!

Katie Labedz

MLC Board Chair

Learn more about the MLC Board of Directors at the BOD Bio page!

Advancing Lean Leadership by Becky Andree, MLC Board Member

Mon, 15 Feb 2021 17:15:31 GMT

When an organization decides to implement Lean, the starting place is usually with a few processes. It is assumed that the ‘right’ behavior will just fall in line as processes are implemented. Organizations that focus primarily on process and minimize or ignore behavior end up facing various obstacles and realize that culture and leadership behavior can make or break a Lean initiative. Do any of these sound familiar?

“I don’t have time to record on a daily management board.”
“The problem-solving board takes too much time.”
“We don’t have time for a Kaizen, I need everyone working to meet customer shipment requirements.”
“The standard work is unreasonable, it takes too long to get the line started up.”

Leaders will need to learn about Lean and the components. They also need to know what to do differently to ensure success for themselves and the organization. If a leader has been with the organization for a decade or more, they likely have years of old habits to unlearn. A Lean system needs strong “Lean management” to implement and sustain, to ensure there is a focus on the process and the results.

A common mistake is assuming if you design the right process, it should always run as designed and produce consistent results. But the real world, isn’t that idealistic. The more complex the process, the more attention and adjustment is needed as you implement and run Lean processes. Leadership behaviors need to be aligned to ensure attention and iteration. Because without it, an organization risks loosing the Lean momentum that was the crucial reason for the change in the first place.

Often leaders are rewarded by the organization (recognition, advancement, and feedback) by knowing the right answer, fixing a problem immediately, and dictating tasks to complete. This behavior and approach is often associated with being a hero or a firefighter. The organization can count on that leader to solve a crisis and keep things moving forward. But McKinsey points out that there needs to be a fundamental shift to asking questions, finding root cause, and connecting tasks to organization purpose.

A shift from the left to the right, isn’t easy. The behaviors on the right require a leader to trade in the superman cap or firehose, a role that has been reinforced, rewarded, and provides an adrenaline rush. Leaders have to develop new skills to engage the workforce, know what questions to ask, and champion Lean processes by linking individual work to organization results.

When I designed Lean Leadership development programs it focused on behaviors that would be needed to support Lean processes as they rolled out. It wasn’t a gradual shift, there was no nudging. It was a series of skills/behavior training that were aligned with the roll out of specific Lean processes. For example, when visual management boards were rolled out, leaders were also trained that every interaction with an employee had a personal and practical need. Leaders learned how to listen when an employee was resistant to the visual management board and to “hear” the practical need (understand, adjust expectations, etc.) and the personal need (heard, understood, respected, etc.). Leaders were learning the new behaviors right along with the new Lean process.

If your organization is struggling to sustain Lean efforts, it might be time to step back, and be a behavior detective. What behaviors are rewarded? Are those the right behaviors to reward? What skills or behaviors do leaders need to do differently to maximize Lean efforts?

Becky Andree

MLC Board Member

CEO of Vertical Leadership Consulting

Learn more about advancing lean leadership.

Happy New Year! by Al Woodliff, MLC President

Mon, 25 Jan 2021 20:09:08 GMT

Wow! 2020 is gone, and it was uniquely dramatic for every one of us. The disruptions in our lives ranged from inconvenience to upheaval to loss of loved ones. Within the MLC, we had to shift our emphasis to online interactions, which have their own advantages, however the high value of live events with great networking, which I know you all value the most, had to be put on hold.

As a new beginning, I want you to enjoy this year in your life with a new MLC experience. As we progress through 2021 with the eventual taming of COVID through vaccinations, the light at the end of the tunnel brightens. You have much to look forward to from the MLC in 2021, including:

A planned live August Annual Conference in Traverse City
Sponsored Lean training from the Sergent Results Group and the Northern Michigan MMTC as part of our new Resource Network
Energetic new Board members who are dedicated to bringing new value to you.

I now have been the MLC President for 2 ½ years, and as it has been an enriching experience. However, I find myself wanting to explore other avenues in my life. So, effective January 31, 2021, I respectfully resign my position with the MLC. I wish each one of you continued success in life.

Best Regards,

Al Woodliff

Community Member

Learn more about what the MLC is providing in 2021 on our Events and Learning page!

2020 MLC Distinguished Service Award Recipients

Tue, 22 Dec 2020 20:24:06 GMT

Congratulations to our 2020 MLC Distinguished Service Award Recipients. The MLC Board of Directors usually honors the recipients during our annual conference. Unfortunately, due to COVID restrictions we were unable to gather at a conference and recognize these amazing volunteers in person.

Here are some comments that came in during the application process:

"Eric is a doer and can be counted on to help where needed; though humble, he has given his time and talents continuously over a long period of time. He spends many hours volunteering and has provided complementary space for the Lean Healthcare Symposium."

"Greg shares his passion for Lean with others, mentoring them on CoP Lean in Legal best practices. He is reliable and enthusiastic, ready to provide feedback and improve. Greg always asks how he can help, and is an outstanding collaborator."

"Tony has an enthusiasm unknown to mankind for the MLC. He volunteers for the MLC in dog years. Tony is a past board member and is currently an advisor to the MLC Membership team. Tony continues to share his MLC knowledge and Lean thinking strategies to help to grow membership."

Thank you 2020 recipients for sharing your time and expertise with the MLC.

Letter from the Chair & Vice Chair of MLC BOD

Mon, 21 Dec 2020 13:00:52 GMT

MLC Community,

This past year has been a very challenging one for all of us, where many of us have personally been impacted in one form another because of the COVID-19 pandemic. Within the MLC family, we have seen many members lose jobs, forced to work extended hours and/or take unpaid furloughs. And in the membership, unfortunately, we have lost loved ones in our families and in our communities due to the virus.

As we near the end of this year we would like to share some meaningful reflection of the recent activities and thinking within the MLC. We have modified much of what we do regarding our events and networking sessions by going completely virtual, and will continue to evaluate our service offerings as business conditions dictate. We have partnered with several people from various organizations such as Dennis Sergent of Sergent Results Group and the MMTC of Northern Lower Michigan, as recent examples. These relationships, in addition to our newly formed Resource Network will lead us through a series of Single Point learning topics, learning themes that we feel confident, will move us through 2021 and beyond.

Before I discuss the current state of the organization, I wanted to send sincere gratitude and thanks to our strong MLC Community--

Thank you to our dedicated members for sticking with us through this time; you are our life-blood given that membership has accounted for a significant amount of our income these last few months.
Thank you to our volunteers that have been organizing, planning, and supporting our day-to-day efforts to offer great services and provide ever-increasing value for our members. A special thanks to Dave Kippen, our volunteer Events Team Coordinator, as well as all of our event team volunteers. We could not host as many MLC Events without you. Also, another huge thanks to volunteer Tony DeCaria who has been a strong voice working with Vanita DeJesus and our Membership Team over the past several months. Without you and your creativity we would not have been able to navigate these challenging waters.
Thank you to our outgoing and new MLC Board Members who have challenged our current condition and are working to create a strong vision with some challenging themes for the next year. Your work is greatly appreciated. In addition, I want to take a moment to welcome our new Board members, Katie Labedz, Becky Andree, Lauren Wisniewski and Josh Foster, who will provide a strong diversity of thought, complimenting the work and efforts of our already talented Board of Directors.
Additionally, our contract staff comprised of our President - Al Woodliff; General Coordinator - Laura Bankowski; and Finance/Website/Social Media Coordinator - Andi Barajas, in conjunction with Richard Love, our Board Treasurer, all have gracefully sacrificed hours to limit our expenses and manage the internal workings of the organization - you truly are our glue that keeps the MLC clicking on all cylinders! Being a near 100% volunteer organization and sustaining for 10 years+ is a testament to all of you and your personal dedication!
And lastly, I want to thank both Ruth Archer, who has recently departed our board for her valuable and significant contributions over the years, and our Secretary, Anne Cram for her time, significant commitment and dedication to the MLC over the last year, as she has decided to leave the MLC at the end of this year. She has provided structure, organization and most of all significant ideas for us to act on as a Board over the last few months. Their collective presence and contributions will be surely missed! The opportunity within the MLC is not unlike what many organizations faced; we struggled putting our strategy to action, and with the recent pandemic, we experienced financial challenges, significant strain on the organization and our overall effectiveness, so as we move into 2021, we will be looking to leverage our membership in new ways, leveraging the talents that exist within the vast network across Michigan. So stay tuned, as we progress throughout the year to see how you can get involved more directly!

If you have any questions, concerns or desires please feel free to reach out to Mike Wiersma, myself or other members of the board. We sincerely need your hearts and minds to support our strategy, so please reach out to us to share your ideas, your time and other valuable contributions to make the MLC and Michigan as a whole, a stronger and more agile community of Lean thinkers.

We look forward to hearing from you!

Thank you, Stay Safe, Healthy, and Happy Holidays to you and yours!

Tony and Mike

Chair & Vice Chair of MLC BOD

Lean at Work: Capacity Planning for Processes Utilizing Lean Techniques by Anne Cram, MLC Board Member

Tue, 10 Nov 2020 13:05:44 GMT

2020 brought unexpected challenges for everyone this year. At the State of Michigan our office — The Office of Continuous Improvement (OCI) was quick to pivot our skills and lend a hand to many aspects of the COVID Response. One of the “asks” this summer was to assist the Department of Labor and Economic Opportunity with preparing to scale up the Workshare division to meet new customer needs.

For those unfamiliar with what workshare is and why they would need to prepare for increased services:

Michigan’s Work Share Program allows employers to restart their business and bring employees back from unemployment. Employers can bring employees back with reduced hours - while employees collect partial unemployment benefits to make up a portion of the lost wages. Employers can also retain their current workforce and are given the flexibility to choose which of their employees are part of a Work Share plan.

It is a great program for Michigan businesses small and large to participate in during times like these.

One of our service lines we developed, and have really seen a demand in lately, is Capacity Planning. This methodology used by our office relies on basic Lean principles and activities to assist work areas in identifying staffing needs for the current or anticipated volume of work (scaling up or down).

In this case, the workshare division anticipated they would need to scale up substantially to effectively meet demand this year. Our methodology included analyzing the current volume of work through process mapping and using Program Evaluation Review Technique (PERT) to identify the Expected Time of tasks in the current process.

Expected Cost Time is found through the following PERT Calculation:

Optimistic Time (O): The minimum possible time required to accomplish a task, assuming everything proceeds better than is normally expected

Most Likely Time (M): The estimate of time required to accomplish a task, assuming everything proceeds as normal.

Pessimistic Time (P): The maximum possible time required to accomplish a task, assuming everything goes wrong (but excluding major catastrophes).

Expected Time (TE): The best estimate of the time required to accomplish a task (the implication being that the expected time is the average time the task would require if the task were repeated on a number of occasions over an extended period of time).

ET = (O + 4M + P) ÷ 6

Once we had a good snapshot of what the current process and volume looked like for the division, we used our Key Assumptions Activity to identify conditions that are assumed to be in place or that must occur for the future process to be successful. An example for this process was:

There is an increased awareness of the Work Share Program and we will never see the pre-pandemic “normal” numbers again (0-5 plans)

At this point, we shifted to facilitation of what the future capacity should look like by first identifying all of the current positions assigned to support the process with their total summary of hours for the year (sick, annual, and holiday leave removed, along with 15% of the hours removed for general administrative duties—per project management standard). In this case, the total hours per employee that they can allocate to tasks is 1,747 hours a year. We then did the following with the data from the PERT activity:

Calculated total hours for each main task/assignment for the year using the expected time data.
Assigned hours to each position. Determined if the hours are split by the team or the same for all.
Unplanned hours are the left over extra or negative hours after all work is assigned.
Divide the negative number of hours by 1,747 and that provided an estimated shortage of positions in the work area,
To wrap up the project, we identified issues and ideas to improve the process for the future and escalated those that would be high impact/low effort sprints for the team to get in place prior to the surge in workload.

The results of this project were recommendations to the divisional leadership for additional positions and quick win improvements to meet the anticipated customer demand and improve the process. The data and methods used to determine positions justified the need for the division to agency leadership.

The real success story of this project are the anticipated results for the customers (State of Michigan businesses and employees). There will be a decrease in the time to process the workshare plan and thus a reduction in wait time for unemployment benefits. Businesses can retain their workforce and employees can make up portions of lost wages. Helping State Departments achieve results like these is what makes Lean so valuable to the State of Michigan and to fellow Michiganders.

Have a Safe, Healthy, and Happy Thanksgiving,

Anne Cram

Lean Process Improvement Specialist, State of Michigan DTMB

MLC Board Member

Do you have a story to share about your Lean Journey?

MLC Communities of Practice by Ruth Archer

Wed, 08 Jul 2020 21:36:34 GMT

Do you belong to a community of practice (CoP)? You may, and not even know it! A community of practice is a group of people informally bound by shared expertise and a passion for a joint enterprise.* At the MLC, we’re constantly developing CoPs for people who are involved in Lean, quality, and continuous improvement efforts in healthcare, legal, manufacturing, academia, non-profits, human resources, government, and utilities, and we’re open to your ideas for new CoPs. We’ve made it easy by developing standard work and sharing best practices across communities.

At the core of the work we do, we leverage our knowledge of continuous improvement using Lean principles for the benefit of our organizations. Belonging to a CoP can be an important part of your personal Lean “knowledge management” system. Whatever your position is, you can benefit from the knowledge and networking you’ll get from participating in a community of practice. As a result of my engagement with colleagues at other organizations, I’ve had new opportunities, sounding boards for problems I encounter, and friends who support me. Through my communities of practice, I’ve learned about resources I wouldn’t have found on my own and had helping hands keep me from stumbling into pitfalls I didn’t know about. Sometimes, it’s only my friends in my CoP who can celebrate a success with me, because others don’t always understand how hard something was to do!

There aren’t any rules about how a CoP should function. As a group, you can meet at a cadence that works for you. Your group can decide if you want to pursue projects, provide training to members, share stories, collaborate, and/or celebrate success. In the MLC, our CoPs develop a charter that guides the activities of the group, but this is a living, breathing document. The group can choose to modify it at any time.

Let us know if you want to join an existing community of practice, or start a new one! We’ll connect you.
*Communities of Practice, 1999, Wenger & Snyder, Harvard Business Review

Ruth Archer
MLC Board of Directors
Technology & Social Media Liaison
www.michiganlean.org

Learn more about the MLC's Communities of Practice!

5 Why Root Cause Analysis by Jason LaFay, DeWitt High School

Thu, 06 Jun 2019 22:02:27 GMT

DeWitt High School students in Jeff Croley's Creative Leadership: Opportunities for Social Innovation class learned how to create a process map for a 5 Why Root Cause Analysis. Chuck Wynn, a Specialist for Operations Excellence at Emergent BioSolutions was a guest instructor for the day of April 1, 2019. Chuck is well versed in Lean management, overseeing quality in the manufacturing division of Emergent BioSolutions (a Lansing area based biotechnology company).

Photo: DeWitt Students Presenting on Bullying Going Unaddressed in Schools

As the result of a Kaizen Blitz activity from last year, Chuck learned of the work of the Creative Leadership class - thanks in no small part to the Michigan Lean Consortium email newsletter! After several communications and a meeting, we decided to collaborate together to teach a problem solving method to Jeff's students. It has long been a goal of mine as a MLC member to expose high school students to ideas of Lean Management. What better way than to have a professional such as Chuck work directly with students to provide a basic overview of some Lean concepts?

The day of Chuck's presentation went exceedingly well! After a 12 minute presentation (Chuck had a student time him: how appropriate), that detailed the fundamentals of a process map to help identify the order and relationship between variables of a problem (along with the highly relevant example of the Flint Water Crisis). Students were instructed to identify a process that either currently is producing positive or negative results. The goal of a process map is for students to develop disciplined system thinking to find solutions to problems or maintain a successful status quo.

Photo: DeWitt Students using Lean Tools to explore the problem of Bullying Going Unaddressed in Schools

Here are the steps students were required to follow:

Instructions:

Pick an event (a problem; a result that was not expected; or something that went very well that you’d like to repeat.
Create a high-level “5-Why Chain” — no less than 5; no more than 7—to identify why the event occurred.
Create a branched Cause Map – do a “deeper dive”, going into as much detail as needed to identify all 1)the factors and 2)their interactions that contributed to the event.

Students were divided into groups of 2-3 to create their process maps. Some of the events they selected were:

Homelessness
Suicide Prevention
Problems with the school's drinking fountains
School related stress

Photo: DeWitt Students using Lean Tools to Explore the Idea of Empathy

Jeff and I circulated throughout the classroom to assist students. It was interesting to see the variables and their sequence on the maps. We encouraged/challenged them to think more deeply regarding the underlying factors of some variables that they failed to consider. Students were engaged and excited to visually represent relationships between variables. Upon completion of the task, students presented their maps to the rest of the class. Chuck pointed on how the students made assumptions that may or may not be true regarding their issue or problem. Students left the class that day feeling good about the activity and that it was well worth their time! Many thanks to Chuck Wynn, Jeff Croley, and the MLC for their support in making this event a reality.

Jason LaFay

DeWitt High School/DeWitt Creativity Group

Learn more about Lean Tools!

Michigan Lean Consortium MLC Community Column

Where Strategy Meets Honesty: Recapping the 8th Annual Grand Rapids Lean Summit

Hidden in Plain Sight: How Fibre Converters Brings Lean to Life Behind the Scenes

The System Behind the System

A Lean Community, Found at the Right Moment

Learning by Doing—and by Listening

We’re All in the Same Boat

Retirement Spotlight: Jim Willems, State of Michigan

Looking Ahead: What to Expect in 2026

Leadership & Student Engagement

A Call to Lead: Interim Board Opportunities

Signature Events & Programs Returning in 2026

Lean Reads & Reflections

8th Annual Grand Rapids Lean Summit

2026 MLC Annual Conference

Lean Six Sigma Green Belt Course – Returning in 2026

Moving Forward with Purpose

2025 Year in Review

Member Spotlight: Gentex Takes First Place at the Global Lean Excellence Competition

Recap: 2025 Lean Excellence Student Competition at the Lean Solutions Summit

Recognizing Our Supporters

Looking Ahead

Featured Organization Spotlight: Brittany Parks Process Consulting (BPPC) & Energy Control Power Lockout (ECPL)

History with the MLC

Why We Choose to Be Members of the MLC

A Human-Centered Approach to Continuous Improvement

Reflecting on the 2025 MLC Annual Conference

✅ Check It Off the List!

Conference Highlights

Inspiring Keynotes

Mix, Mingle, and Cruise

Breakouts, Panels, and Big Thinking

Bonus Session: Big Thinking Box

Friday Gemba Walks

A Community That Shows Up

Thank You

Looking Ahead: 2026 Annual Conference

Member Spotlight: Orchid Orthopedic Solutions

MLC Welcomes New Board Leadership and Directors

MLC Member Spotlight: Consumers Energy

MLC Member Spotlight: Sebright Products, Inc.

MLC Member Spotlight: Dematic’s Victory at the 2024 Lean Excellence Competition

2024 Distinguished Service Award Winner

Celebrating Success at the 2024 Annual Conference!

An Amazing Event!

Check It Off The List!

THANK YOU TO OUR PRESENTERS

Mark Your Calendars for 2025!

Celebrating Success at the GR Lean Summit: Less Is More

Systems Thinking for Lean Practitioners

What are the key attributes of system thinking?

Why use systems thinking?

TAKT TIME 101: We Got The Beat Recap

The MLC hosted an online Coffee Chat with Beth Crowley Presenting Takt Time 101

Takeaways

Gemba Walk Recap—Granger Construction

Gemba Walk Recap—Cummins Sales and Service

From the Chair—June

Summer in Michigan is the best!

From the Chair—May

Subject Matter Expert of The Month—May

From the Chair— April 2023

Happy Spring!

Subject Matter Expert of The Month—Emir Avdic

Emir Avdic was our March Coffee Chat Subject Matter Expert.

Subject Matter Expert of The Month—Sakeena Rashid

Sakeena Rashid was our February Coffee Chat Subject Matter Expert.

Student Spotlight— Fiona Boyle

Student Spotlight

From the Chair—February 2023

Subject Matter Expert of The Month—Cheryl Underwood

Student Spotlight—Grant Pinto!

From the Chair

Happy New Year! I hope this note finds you happy and healthy!

For the Love of Lean, Holly Plaga, Michigan Lean Consortium Chair

Subject Matter Expert of the Month—Brittany Parks

Our Coffee Chat Subject Matter Expert of the Month was Brittany Parks.

Thank you for sharing your knowledge with the Coffee Chat participants!

From the Chair

Subject Matter Expert of the Month—Kevin Olds

For the Love of Lean,
Holly Plaga,
Michigan Lean Consortium Chair