The Lean Learning Center was founded by Andy Carlino, Dennis Pawley, and Jamie Flinchbaugh.
Team member bios:
Bill Artzberger has over twenty-five years of experience in real-world senior management, including CIO, VP, President and CEO. He has worked with thousands of individuals from the boardroom to the shop floor, in virtually all sectors of industry.
Bill is a partner at the Lean Learning Center. He specializes in Lean Training, Consulting in Lean Manufacturing, Project Management, Kaizen Implementations, Shop Floor Management, Information Systems, and Supply Chain Management.
Bill earned his Master of Business Administration degree (MBA) from Wayne State University in Detroit, Michigan with a major in management and a minor in marketing. He received a Bachelor of Business Administration degree (BA) from Walsh College in Troy, Michigan with a major in Information Systems and a minor in finance. He also holds an Associate of Applied Science degree (AS) from Oakland Community College in Farmington Hills, Michigan with a major in systems analysis. Bill is ITIL Certified, a certified Lean Six Sigma Black Belt and a PMI certified Project Management Professional (PMP).
Bill brings extensive strategic, project management, lean manufacturing, and information technology experience to The Lean Learning Center. He is also co-author of the top selling Lean book Driving Operational Excellence.
- Clients have included: DaimlerChrysler, General Motors, DTE Energy, Ford Motor Company, Spirit Aero Systems, GE, American Airlines, and BlueCross BlueShield
- Provides information systems analysis, project management, portfolio management, organizational assessments, and due diligence for the private equity investment community
- Holds of two patents and has been published dozens of times
- Regular speaker on college campuses and corporate events around the country
- Enjoys a reputation as a consultant with a unique combination of a broad business background, strong manufacturing experience, and deep technical knowledge
Tom Bechtel has more than thirty years of industrial and consulting experience in all aspects of manufacturing operations and Enterprise Resource Planning (ERP). In his work as a consultant, he has provided lean training, leadership coaching, kaizen workshops, project management and ERP implementation to a variety of industries.
Tom graduated with degrees in both math and physics and electrical engineering from Penn State University. Tom is also a certified “Fellow” in Production and Inventory Control (CFPIM) by APICS.
He began his career as a shop floor supervisor and trainer for GE subsequently working in senior operations management positions with Nortel and Mitel and ultimately Vice President of Operations for Kaval Wireless Technologies before joining the ranks of the consulting community.
Tom is an accomplished trainer, mentor, facilitator and consultant for both Lean Manufacturing and ERP strategies and practices.
Tom’s wide range of experience in electronics, healthcare, food processing, automotive and gas/electric utilities has afforded him the advantage of being able to help companies with the blending of shop floor process improvement with business implementation enhancement. Many of his projects include:
- Project management to implement LeanERP, concurrent engineering, synchronous flow lines, new practices for design & build of complex products
- Implementation of production work cells and kanban systems for GE Canada and GE Puerto Rico
- Earlier implementation of ERP systems for a variety of companies in a variety of industries
- Forensic analysis and resolution of material production control systems
- Facilitation of Lean Learning Laboratories in food processing and auto manufacturing
- Lean materials development and training for gas/electric public utilities, food processing and healthcare
- Facilitation of over 100 kaizen workshops in a variety of industries from repetitive manufacturing to patient delivery in healthcare
- Featured speaker and trainer for APICS
An internationally recognized consultant, educator and speaker, Andy Carlino has over twenty years experience in real-world senior management, including president and COO, and is recognized internationally as a lean expert and trusted advisor. Over the past 23 years he has worked in virtually all sectors of industry and is well known for helping companies implement and sustain organizational change. He is as comfortable and successful in the boardroom as he is on the shop floor and individuals and companies frequently seek his counsel.
Andy holds a Bachelor of Science degree in Engineering and a Bachelor of Arts degree in Psychology and is a member of ASQ, AME and other industry and professional associations.
Andy is a frequent keynote speaker for a variety of professional organizations, industry conferences and company events. He is co-author of The Hitchhiker’s Guide to Lean: Lessons from the Road and has authored numerous industry publications, blogs and videos specific to the Principles and Practices of Lean Systems Implementation.
The co-founder and partner of the Lean Learning Center, Andy’s experience and accomplishments are wide and varied including:
- Trusted Advisor to senior leadership of some of the largest global organizations.
- Prior to co-founding The Lean Learning Center, he founded Achievement Dynamics which specialized in training, education and consulting in the areas of Lean Systems Development, Kaizen Implementation, Lean Learning Laboratories, Executive/Leadership Coaching, Program Development, Shop Floor Management, Leader Standard Work, Value Stream Management, Supplier Development, and Development of Internal Lean Specialists..
- Twenty-three years as an industry leader responsible for the development and application of leading edge lean initiatives widely accepted and adopted nationally and internationally.
- Successful engagements include, Harley Davidson, BISSELL, Siemens, DTE Energy, RSR Quemetco, BlueCross BlueShield, Johnson & Johnson, Irish Rail, Network Rail (UK), Land O’Lakes/Purina, DANA, Guidant Technologies, Bissell, Chrysler Corp, Glanbia Foods, AGCO and many more.
- Developed and applied the structure tools, and techniques for enterprise-wide Direct Observation
- Organizational and operational assessments across all types of industries and enterprises.
- Due diligence for the private equity investment community.
Melissa Curtis-Hendley is the Instructional Design Director for the Lean Learning Center. Her diverse background includes designing training initiatives for and consulting with numerous manufacturing and non-profit organizations. Prior to joining the Lean Learning Center in 2006, she served as a human resource generalist for a county community bank.
Melissa holds a Bachelor of Arts degree as well as a Master of Training and Development degree, from Oakland University in Rochester, Michigan. She also earned a professional certification in human resources from the Human Resource Certification Institute in Alexandria, VA. Melissa currently lectures on instructional design methods and program evaluation in the Human Resource Development department at Oakland University’s School of Education and Human Services.
Melissa’s responsibilities with the Lean Learning Center include designing customized curriculum content and delivery methods for client and public courses, planning and evaluating design, delivery and instructional flow of training and instructional products and conducting needs analysis to identify learning audiences. She designed the Lean Learning Center’s Single Point Lesson package as well as the Center’s Lean Quad and Beer Game simulations and is currently developing the Lean Learning Laboratory package. Additionally, Melissa has assisted in facilitating lean workshops for Burger Boat Company and Agilent Technologies and provides support for Lean Experience® classes held at Simmons Foods in the U.S. and Intel Corporation worldwide.
She also engages with clients to facilitate content development reviews, and defines project tasks, identifies resources required, assigns responsibilities and monitors progress against established timelines. Her instructional design projects for the Lean Learning Center include:
- A leadership course for United Technologies
- A lean human resources course for Fidelity Investments
- Learning activities and participant guide for the Lean Learning Center’s, Tactics of Lean Innovation public workshop
- Facilitator, participant guides and game materials for the Lean Learning Center’s Mouse Trap game
- Materials and participant guides for the Lean Learning Center’s Leading Lean workshop
- Facilitator guides and reference materials for Amazon.com Aces lean course curriculum including Kaizen Essentials, Leading Lean Events and ACES for Leaders
- Participant guides for LM Glasfiber, AGCO, Network Rail and Irish Rail lean workshops
- Learning activities and participant takeaway materials for Timken’s supervisor training series
- Learning activities, facilitator guides and participant takeaway materials for Oshkosh’s Operating System workshops
Marcos Fabris is a lean manufacturing professional with solid production management and quality management experience in industries including shoes, metal mechanics and manufacturing. He has been introducing lean manufacturing tools and developing projects since 2000.
Marcos holds a degree in Mechanical Engineering from PUCRS and a postgraduate degree in Production Management from UFRGS. He has completed additional seminars and course work including the Lean Experience from the Lean Learning Center, Six Sigma – Green Belt from Werkema, Trading from Paulo Pizarro, and Endomarketing from Unisinos.
Previous to joining the Lean Learning Center, Marcos was a director and consultant at Deploy Management Consulting where he developed and coordinated lean transformation projects for metal mechanics, footwear, textile and drinks industries in Northeast and South Brazil. At GS Consulting Service, LTD., Marcos trained more than 60 clients of GS Brazil and was in charge of the administrative, commercial and technical areas of Northeast Regional. An Industrial Director at MR Footwear Industry and Trade LTD, Marcos managed the whole process with three production lines with a capacity of 3,000 pairs a day, and supervised a staff of 400 employees.
Marcos’s experiences in lean management include:
- Consulting in the areas of production management and quality management, focusing on improvement and rationalization of processes, ISO 09001-2008 and development of Lean Manufacturing
- Planning and analyzing production flow, cost/estimation control, supplying, manufacturing procedures and time measurements
- Referencing planning and analysis of production flow, cost /estimation control, supplying, working out of manufacturing procedures and time measurements
- Developing strategic planning with the use of BSC and methodology used in big and medium enterprises
Jamie Flinchbaugh is co-founder and partner of the Lean Learning Center, bringing successful and varied experiences of lean transformation as both a practitioner and facilitator. Under the leadership of Jamie and the Center’s senior managers, the Lean Learning Center has become one of the most recognized and premier lean providers in the world.
Jamie is a graduate fellow of the highly regarded Leaders for Manufacturing Program at the Massachusetts Institute of Technology where he received a Master of Business Administration degree from the Sloan School of Management, and a Master of Science degree in Engineering. He has also received a Master of Science degree in Engineering from the University of Michigan and holds a Bachelor of Science degree in Engineering from Lehigh University.
Prior to founding the Center, he worked at DTE Energy, parent to Detroit Edison, as a lean thought leader to help transform the operations, leadership and thinking of the utility industry towards a philosophy of lean systems. Earlier in his career, Jamie was part of the development, training and implementation of the Chrysler Operating System, a widely benchmarked lean change program.
Jamie is also the founder of the Old Dutch Group, LLC, an investment company, and a principal of Cobra Motorcycles. He also serves on the board of directors of S&S Cycle, Inc. and is an investor in Flinchbaugh Engineering, Inc.
Jamie resides in Riegelsville, Penn. with his wife, Jill, and children Emma, Jack and Ben. You can also follow Jamie on his blog at www.jamieflinchbaugh.com.
Jamie’s experience and accomplishments are wide and varied including:
- Operational experiences, including product development production, maintenance, quality, materials and manufacturing engineering, at every level from the board room to the shop floo
- Co-authoring The Hitchhiker’s Guide to Lean: Lessons from the Road, a best-selling lean book, with Andy Carlino
- Consulting clients that have included Intel, Intevac, Simmons Foods, Simmons Mattress, Numonyx, Freescale Semiconductor, Del Monte, Hallmark, M&M Mars, Amazon.com, Harley-Davidson, United Technologies, Trane, AVL North America, Detroit Medical Center, Takasago, Intermatic, Schwak, Dana, Universal Forest Products and ZF Industries
- Chairing the Board of Advisors to Oakland University’s Pawley Institute
- As member of the Lehigh Leadership Council at Lehigh University, receiving the University’s prestigious Alumni Award for outstanding service in 2004
- Receiving the award Entrepreneur-in-Residence in 2006, and delivering the keynote address for the Honors Convocation at Lehigh University
Chris McKellen is a Senior Consultant with the Lean Learning Center, based in the UK. He started his career in the machine tool industry and was then involved in setting up a new factory to manufacture air compressors, before taking up a group role in manufacturing engineering. At a specialist diesel engine manufacturer he gained an insight in to the benefits and pitfalls of the early flexible manufacturing systems and the need to increase productivity on such systems.
After joining the automotive division of a major US based group, he learned that some of the traditional planning tools and measures used throughout manufacturing industries could sometimes create major problems within the business. This realization, coupled with the need to improve productivity in a highly unionized environment, led to his keen interest in Lean Manufacturing, the empowerment of employees and the constant drive to become World Class.
He moved to the People’s Republic of China to take total responsibility for setting up and the start-up of a new World Class manufacturing plant for automotive components. This plant is now recognized as the benchmark plant for quality and productivity in the turbocharger business. Following his return to the UK, he coordinated the six-sigma / operational excellence program across a number of European plants before carrying out consultancy assignments in the area of Lean Manufacturing.
He completed a long term assignment with another major US based automotive component manufacturing company where he trained employees in modern manufacturing techniques, managed major projects and introduced the Lean Manufacturing concepts and philosophies to traditional purchasing and materials departments and the supply chain.
Since 2001, Chris has developed long-term relationships with many organizations, in the UK, Europe and Asia, both large and small to help them implement service and business improvement techniques. He passionately believes that service improvements need to be implemented by teams of ‘real’ people in their workplace – not by individuals sitting in offices.
Susan Pleasant is a partner of the Lean Learning Center specializing in lean systems, procurement, manufacturing, supply chain, quality, and customer service. Formerly senior vice president of manufacturing and supply chain for Wise Foods, a $400 million manufacturer of snack foods, she was responsible for procurement, manufacturing, contract manufacturing, warehousing, transportation, quality, and engineering. While at Wise she reduced COGS 4.5% net of escalating commodities pricing by reducing manufacturing wastes, redesigning manufacturing assets and supply chain, transforming scheduling processes, and implementing restructured carton and packaging configurations.
Susan holds a Bachelor of Arts degree in Biology from Winthrop University in Rock Hill, S.C. She is a graduate of Lean Leadership (Lean Learning Center), Leading Product Development (Harvard University), Principle Centered Leadership (Covey Leadership Center) and Leadership Development Program (Center for Creative Leadership).
Prior to joining the Lean Learning Center, Susan developed and implemented training and lean systems for a global provider of wind turbine components. She was also responsible for the complete organization realignment of a major auto transport company to combat the impact of reduced volume and higher costs.
As senior vice president of Consolidated Container Company, an $850 million manufacturer of plastic bottles, Susan improved EBITDA 5.6% at 10 targeted lean system plants with changeover reduction, waste elimination processing, workstation organization, and operating metrics. She led the design and implementation of new products commercialization process at three other companies resulting in 100% of products being launched on time and under budget while delivering planned inventories.
In addition, Susan served as senior vice president of Brach and Brock Confections, vice president of operations Lifesaver Company for Nabisco Holdings Corp. and director of operations for Frito-Lay.
As partner and senior consultant with the Lean Learning Center, Susan’s experience includes:
- Developing and launching of lean leadership training materials for Amazon.com
- Developing and implementing of A3 performance and systems improvement processes for leadership at Intel Corporation delivering instrumental improvements in ’09 results
- Coaching business leaders on lean systems at Intel, United Technologies and General Dynamics
- Facilitating the complete organization realignment of Allied System Holding to combat the impact of reduced volume and higher costs
- Fostering improvement of cycle times 46% in LM Glasfiber’s wind turbine component plant in India during lean production system implementation
- Facilitating a Kaizen workshop to increase speed and reduce wastes in commercialization processes for Ocean Spray
- Conducting Kaizen workshop training for Continuous Improvement and Blackbelt leaders at TAMKO.
Al Pond is a senior consultant for the Lean Learning Center and has collected nearly 50 years of experience, between Ford, his consulting practice, as founder of ALX Consulting and teaching at the University of Michigan Dearborn. Al developed his lean skills during thirty-eight years with Ford focused on operations, engineering and strategic planning. He retired in 2002 as the executive founding member of the Ford Production System. In his second career as a consultant and teacher, his focus has been on executive leadership and implementation of lean systems based on his experiences with the Ford Production Systems and expertise in the Toyota Production System.
Al graduated with a BS in Management and an MBA from the Eastern Michigan University. He attended Executive Development classes at the University of Michigan and Lean Enterprise Systems at the University of Tennessee. He is a lifetime Certified Manufacturing Engineer by the Society of Manufacturing Engineers (SME).
Al holds the distinction of being one of an elite group of manufacturing executives that actually started as a union represented hourly worker on the shop floor. He progressed through the skilled trades via the apprenticeship program and then on to engineering and management. This wide variety of experience, starting as a production worker and progressing to a senior manager, gives him a most unique perspective and background as a lean change agent.
Al’s extensive experience from plant floor to executive suite include: Manufacturing Operations and Engineering, Product Development, Strategic Planning and Employee Development. In 1993 he was recognized by the American Society for Training and Development (ASTD) for outstanding program achievement in the automotive industry as the author of Ford’s New Employee Orientation Program.
Al’s experience and accomplishments are wide and varied including:
- TPM prize award by Japanese Institute of Preventive Maintenance at the Charleville Climate Operations in France
- Ford’s senior coach and mentor for lean implementation in South America, Asia-Pacific, component operations (Visteon) and major new vehicle programs.
- Responsible for developing the lean curriculum and training for the staff of Oakland University, one of the early attempts to institute lean into academic operations
- Lean trainer and workshop facilitator for a semi-conductor provider in Japan, Malaysia and China
- Lean trainer and management coach for a leading worldwide snack food manufacturer
- Trainer and executive coach for LM Glassfiber’s North American Windmill operations
- Kaizen facilitator, Coach and trainer for the Detroit Medical Center and Sinai Grace Hospital
- Clients have included, AGCO, AlphaUSA, Dana Corp, Detroit Medical Center, Fidelity, Freescale Semiconductor, Genzyme Pharmaceutical, M&M Mars, J.D. Power, Limited Brands, Oakland University, Oshkosh Corp, Sinai Grace Hospital, Seneca Foods, and Timken Corp.
A lean consultant and coach for the Lean Learning Center, Jim Sonderman has more than 18 years of experience in the automotive industry. He was exposed to lean systems early in his career while working closely with Toyota as a parts supplier to the Georgetown, Ky. and NUMMI assembly plants. He was recognized as an early adopter of lean thinking and was selected to aid in the development of the Delphi Manufacturing System. He served several years as a Kaizen Leader in the plant driving excellence in manufacturing.
Prior to joining the Lean Learning Center, he held the positions of technical manager, lean supplier development and production systems advisor at Delphi World Headquarters. Earlier in his career, he served as general supervisor and production systems leader at Delphi Chassis Systems.
Jim spent approximately nine years in management and nine years in direct continuous improvement roles supporting the lean transformation of Delphi. He chaired the Operational Availability Circle of Colleagues and led in the development and dissemination of Total Productive Maintenance strategies globally. He spent the last four years of his career in automotive as a technical manager in the Delphi Supplier Development Organization coaching and assisting suppliers in his or her own lean transformation.
Jim holds a Bachelor of Science degree in operations management from Ohio State University in Columbus, Ohio. He currently resides in Lake Orion, Mich. with his wife Michelle and daughter Samantha.
Jim’s current experience with the Lean Learning Center includes:
- Leading learning labs at Northrop Grumman
- Lean training for executives and managers in Texas, Arizona and Malaysia and numerous kaizen events in facilities in the U.S., Europe and Asia for Freescale Semiconductor
- Learning labs and lean coaching, Fox River Mills; Kaizen boot camp and lean training for managers and leaders for Trane in their U.S. and Mexico facilities
- Leading Kaizen events, learning labs and lean coaching at Foster Dairy Farms
- Leading learning labs and plant assessments, RSR Corporation
- Lean consulting for AGCO
- Leading set-up reduction workshop at Johnson and Johnson
- Leading Kaizen boot camps for AVL North America