Implementing Lean - the lean conference - Feb. 26-28, 2019 - Roanoke, Virginia
Implementing Lean - the lean conference - Feb. 26-28, 2019 - Roanoke, Virginia



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Tuesday, Feb. 26
1-6 p.m. ELDOR Logo Pre-Conference: ELDOR Tour

We will tour ELDOR Corporation in Botetourt, Va., as a special pre-conference experience. ELDOR is one of the top three world leaders in ignition coils (estimated about 50 percent of market share for that component segment) and opened up production in their Virginia plant this past fall.

After the tour concludes at ELDOR, the group will be visiting Ballast Point East Coast Brewery, tasting room and kitchen, also in Botetourt. The group will tour Ballast Point’s massive production facility and network and/or partake in the many food and beverage options at the restaurant. Meals and beverages on your own. .

12:30 p.m. Please arrive at The Hotel Roanoke & Conference Center and prepare for departure to ELDOR
1 p.m. Depart from The Hotel Roanoke & Conference Center for ELDOR Corporation in Botetourt, Va.
2 p.m. Arrive at ELDOR Corporation
3:30 p.m. Depart ELDOR, arrive at Ballast Point
5 p.m. Depart Ballast Point
6 p.m. Arrive at The Hotel Roanoke & Conference Center
Wednesday, Feb. 27
8:30-9 a.m. Registration and Continental Breakfast
9-9:30 a.m. Welcome Address - Mike Leigh, OpX Solutions, llc.
9:30-10:15 a.m. Keynote - Modena Henderson, MHA - Vice President, Laboratory Services, Carolinas HealthCare System
We are honored to have Modena Henderson as one of the Lean Conference keynote speakers. Henderson is responsible for laboratory services at Carolinas HealthCare System's metro-area hospitals and health pavilions, overseeing reference laboratory services for more than 1,000 physicians, nursing homes and hospitals through the Carolinas Laboratory Network.

There are key principles of Lean from the healthcare system that can be applied to any industry. Henderson will focus on the importance of respect for people and how to move toward a culture of process improvement.
10:15-10:30 a.m. Break
10:30-11:15 a.m. Breakout #1

Option 1: Pre-Conference Tour Discussion - Mike Leigh, OpX Solutions, llc.

Option 2: Moving from an Expert to a Strategic Facilitator with Jeff Smith, Fortify Leadership Group
This fast-moving, engaging and interactive speech will explore employee engagement, serving leadership and ways to grow your leadership toolkit. We will learn the keys to engagement and tips for how leaders can increase retention, productivity and employee well-being by incorporating a few new practices into their leadership style. This will help the leaders move from their comfort zone of technical knowledge to learning tools and tips about influence and leadership.

Option 3: Toyota Kata: Changing Culture Through Problem-Solving Routines with Jeff Fuchs, Office of Customer Experience, U.S. Dept. of Agriculture, & Executive Director, Maryland World Class Consortia
Changing a whole organization's culture to embrace Lean is a huge challenge, especially when we see what this implies: every person scientifically striving toward improvement goals every day. Toyota Kata - a pattern of learning and adaptation - is becoming widely recognized as a powerful technique to improve, coach and move toward goals in unfamiliar territory. In this fast-paced overview, participants will learn how to use Toyota Kata to change habits, mindsets and build Lean cultures.

11:15 a.m.-12 p.m. Breakout #2

Option 1: Advancing Lean Leadership with Angie O'Brien and Mary Talley, City of Roanoke
The City of Roanoke is a strong, successful champion of Lean practices. Angie O'Brien and Mary Talley are both certified Lean Practitioners for the City of Roanoke. Talley is also a Lean Six Sigma green belt practitioners. Together, they have a number of years of experience to share. They will discuss how to use Lean and continuous improvement methodologies to encourage and enhance leadership skills in employees at all levels. Explore how leading and implementing small projects builds and reinforces successful leadership techniques. Learn how to use Lean and continuous improvement methodologies to encourage and enhance leadership skills in employees at all levels.

Option 2: Lean Projects as an Experiential Learning Tool with Natalie Cherbaka and Lean project teams, Virginia Tech
Cherbaka from Virginia Tech's Center for High Performance Manufacturing and Industrial and Systems Engineering (ISE) will introduce student teams who will present real-world applications of Lean tools. You will:

  • Receive an introduction to the concept of experiential learning
  • Learn how Lean principles are taught in conjunction with a Lean project
  • Experience various Lean metrics and actual project results
Option 3: A Journey of Lean in the Utility Industry with Tony Miller, Appalachian Power Co. (APCo)
Review of APCo's six-year journey engaging front line employees and moving the culture in a positive direction. After introduction of the LMS this past year within APCo the focus has been to establish standard work among the work groups. Examples will be given of standard work developed within our teams and how difficult that can be in the electric industry.

12-1 p.m. Lunch & Keynote - 2-Second Lean with James Smith and Tom Zbell, GENEDGE
The 2-Second Lean method will help to change the culture of your organization to one where everyone is involved and improving their process – every day. Doing this will reduce the waste in your processes, freeing up resources to take on new tasks.
1-1:45 p.m. Breakout #3

Option 1: Root Cause Analysis in Excel® with ThinkReliability with David Williamson, Leverage Point
Get an overview of a powerful systems thinking approach to root cause analysis with some real world examples. The Cause Mapping process and free Excel® template from ThinkReliability can be used to facilitate effective root cause analysis in Lean process improvement and many other kinds of projects.

Option 2: Triumphs and Challenges with Lean Implementation in the Bioprocess Industry with Chris McDowell PhD and Lesley Kees, Novozymes
Novozymes Salem has been on their lean journey for more than 10 years. Novozymes is building on a foundation of daily performance management and kaizen activities and implementing an annual strategy deployment process to identify and prioritize improvement initiatives across their value streams. Chris McDowell and Lesley Kees will highlight the successes and challenges of the site’s lean journey and explore the key concept of flow that is integral to the site’s future lean Development.

Option 3: Bridging Language Gaps with Lean with Baraka Kasongo and Elizabeth Hord, VOLATIA
In the United States, over 60 million people speak a language other than English at home. To serve this population, organizations of all sizes and in every industry are confronted by the daunting and time-consuming task of finding, requesting and managing interpreters and translators. The resulting workflows are full of waste at every touchpoint. This session will highlight a success story that demonstrates how Lean principles can be used to overcome linguistic and cultural disparities.

1:45-2 p.m. Break
2-2:45 p.m. Panel + Q&A Session
Moderator: Mike Leigh
Panel: Modena Henderson, John Dyer, Nelson Teed
Subject: Lean Leadership and Early Adoption - Q&A from attendees
2:45-3:30 p.m. Breakout #4

Option 1: Lean Culture Utilizing Change Agents with Emily Dorr & Arnold Gates, Altec
Creating a culture of change is critical to implementing Lean within your organization. In this session, you will learn why change is important to your business, how to identify roadblocks in implementing change and how you can become a more effective change agent.

Option 2: Lean Management, Total Productive Management (TPM), Six Sigma and How They Work Together to Improve Your Results with Urs Buehlmann, Virginia Tech
The terms of Lean are often thrown around in discussions among manufacturing and management specialist. However, the average industry participant struggles to keep up with all the buzzwords, to separate the odd from the helpful, and to fully grasp their significance for their operation. We will discuss some of the more helpful systems and illustrate their workings.

Option 3: Value Stream Mapping Administrative & Office Processes with Mark Oakes, Merit Medical
Value stream mapping of an administrative process is different from a manufacturing process. This session will highlight those differences and provide a foundation for mapping these processes that move paper or electronic documents through multiple hands, reviews and approvals. Once mapped, the current state can then be fully reviewed for opportunities to improve the process and create a future state and an associated improvement plan.

3:30-4:30 p.m. Reception & Networking
Thursday, Feb. 28
7:30-8:30 a.m. Lean Coffee
Join us for this special morning session of Lean Coffee, facilitated by Andrea Ross, Process Improvement Manager for the Virginia Department of Health. At Lean Coffee we will discuss what you’ve learned so far and learn a new Lean method for conducting a meeting.
8:30-9:15 a.m. Breakfast and Keynote
Your Organization is Implementing Lean: So What? with John Dyer, Process Innovations, Inc.
Why is your organization doing Lean, Six Sigma or any other improvement effort? Join John Dyer as we take a dive into the portions of the improvement process that are often misunderstood or completely overlooked: direction and culture. There are four components that will help clarify the direction and put into words a description of your culture. We will discuss the differences between Mission, Vision, Strategy and Values and look at how each will impact your improvement efforts.
9:15-9:30 a.m. Break
9:30-10:15 a.m. Breakout

Option 1: Examples of Lean in Businesses with Margaret Deck, Virginia Tech
Explore examples of using various methods of gathering process data (VSM, spaghetti charts, identifying types of waste, Pareto analysis) to identify opportunities for improvements using Lean tools such as 5S, standard work, visual management and more. These are real life examples from businesses in the New River Valley, from senior student teams in the College of Business.

Option 2: Revitalizing Continuous Improvement with Cynthia Popernack & Lynn Miller, Canon Virginia, Inc.
Need to refresh your continuous improvement efforts? We'll share Canon Virginia's system for reviving our lean culture. The three-part approach includes a cross-functional planning team, a training methodology which incorporates both people and tech skills, and gemba events where trainees execute lean improvements. Driving this revitalization is hands-on engagement, support and direction of top-level management. It's not a lean training program, it's a mindset!

Option 3: Kaizen in Action! (in Local Government) with Chad Sweeney and Jessica Webb, Roanoke County
Learn about the Kaizen concept and see first-hand how two local government processes were improved with a two-day Kaizen event.

10:15-10:20 a.m. Break
10:20-11 a.m.

Option 1: Visual Workplace in Custom Manufacturing with Kyle Moyers and Kara Contessa, Altec
There comes a point in custom manufacturing when point of use storage is no longer effective. When more time is spent communicating needs and the amount of inventory in your area consumes your value added production space, other lean measures need to be taken. Creating one central location for parts will optimize space, but how do you then signal the type of product, quantity, and timing needed for each area? This session will review a case study that shows how automated signaling and visually managed part presentation out of a central part location improved communication and production efficiency.

Option 2: Top Ten Do's and Don'ts for Lean Six Sigma Implementation with Nelson J. Teed, Manufacturing Technology Center
Life is a remorseless teacher. You learn a lot over 35 years of hands-on experience planning and leading Lean Six Sigma implementations in dozens of organizations of every size and type. Some of these companies achieved enormous improvements, but many met with only moderate success while some achieved no lasting benefits at all. Why? What really determines success or failure? The Top Ten Do's and Don'ts reveal the answer.

Option 3: Advanced Manufacturing Learn & Earn with Norm Mortensen and Kim Knapp, BridgeValley Community & Technical College
Learn about the partnership between BridgeValley Community & Technical College and Toyota in West Virginia. Selected students enrolled in the Advanced Manufacturing Technology program attend classes two days per week and work at Toyota three days per week, giving students the opportunity to apply classroom learning to real world experiences.

11 a.m.-12 p.m. Closing Remarks

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