Lean leadership boot camp

September 9, 2019 | 8:00 am to September 13, 2019 | 11:30 am
Contact AME: 224-232-5980 | conference@ame.org
Student Member Fee: $100
Member Fee: $1,649
Non-Member Fee: $1,799


Vulcan, Inc.
339 East Berry Avenue
Foley, Alabama

Lean is a systematic approach to eliminating waste and creating flow within an organization to improve overall customer value. The foundation for lean success is a problem-solving culture, based on coordinated process improvement and people development. The Boot Camp teaches not only lean tools, but also offers proven leadership techniques for implementing lean in your organization, managing culture change, and developing continuous improvement engagement throughout your workforce. Benefits of implementing these techniques include coaching and developing team members who actively pursue improvement in safety, quality, productivity, and intentional employee engagement.

Will need to provide proof of citizenship for the tour (Passport or birth certificate and driver's license)


Vulcan, Inc. consists of Vulcan Aluminium, Vulcan Aluminum Mill, Vulcan Metal Stamping, Vulcan Signs and Vulcan Utility Signs. These five divisions support the core business of manufacturing outdoor-durable utility signs, markers and related products. https://www.vulcaninc.com/


Monday-Thursday 8 a.m. – 4:30 p.m.
Friday 8 a.m. – 11:30 a.m.

Monday:  Creating a Foundation of Stability and Leading through Lean and Value Stream Mapping (VSM)
Day 1 in Brief: The leader’s role in using fundamental lean principles is demonstrated and reinforced using a hands-on Buzz factory simulation. Value stream mapping is introduced to enable one to grasp the current condition and develop breakthrough challenges aligned with the company vision and goals.
Detailed Description: The foundation of lean is standardization and stability. The 8 wastes are introduced coupled with lean tools & countermeasures. Value stream maps provide the Plan in the PDCA (Plan, Do, Check, Adjust) improvement cycle. Value-stream mapping gives leaders a picture of the entire production process, both value and non-value-creating activities. The VSM process consists of identifying value streams/product groups, mapping a current state of material and information flow, assessing waste in the process, and designing a desired process.

Tuesday: Kata – Improvement & Coaching
Day 2 in Brief: Application of the Toyota Kata discipline to drive continuous improvement, focusing on habits, rapid PDCA cycles, and sustainability of continuous improvement initiatives utilizing the Buzz simulation. Teambuilding exercises reinforce the improvement Kata process and the communication skills essential for the Coaching Kata.
Detailed Description: Leaders need the dual ability to improve processes and develop people to create and sustain a culture of improvement. A Kata is a discipline through which the lean leader serves as a coach/mentor to develop team members. This training introduces the Improvement & Coaching Katas. In the Improvement Kata, participants follow a four-step, scientific pattern which challenges team members to strive for improvement. Through the Coaching Kata, participants learn to follow a mentoring methodology that develops a leader’s skill to coach while simultaneously developing team members’ knowledge. The Kata process is based on the PDCA scientific method through which actions are planned, tested, measured, and adjusted towards achievement of a target condition.

Wednesday Morning: United Technologies Tour (8 - 11 a.m.)

Wednesday Afternoon: Leading & Sustaining with Eight-Step Problem Solving
Day 3 in Brief:
 Utilize a lean management framework and incorporates eight-step problem solving along with exercises in problem solving and teambuilding.
Detailed Description: Leading and sustaining lean involves a framework of strategic alignment, disciplined culture and operational transparency. The lean management system is comprised of elements including visual systems, process metrics, leader standard work, A3 problem solving, accountability boards, suggestion systems and gemba walks. This training is designed to teach a disciplined process to foster a problem-solving culture, to build accountability and to reinforce PDCA thinking and management. Combining the Kata process with the leading and sustaining lean system builds the disciplined structure for successful lean implementations.

Thursday: Importance of Standards – 5S, TWI Job Methods & Job Instruction:
Day 4 in Brief: Use a Quick Changeover Simulation to stress the importance of stability & standardization as the foundation for problem solving
Detailed Description: The foundation of continuous improvement is stability & standardization. Before a problem — a gap from a standard — can be identified, a standard must be in place. Utilizing a stamping press simulation, participants use the TWI Job Methods questioning process to breakdown the changeover. Stability is introduced via the 5S methodology (Sort, Set-In-Order, Shine, Standardize, and Sustain). PDCA Kata iterations are used to improve towards the target conditions. The four-step Job Instruction is demonstrated stressing important steps, key points & reasons for key points as the standard for consistency in training methods.

Friday: Lean Culture & DiSC Profile (8 - 11:30 a.m.)
Day 5 in Brief: Take a systems perspective approach to people processes. The DiSC profile allows one to know their preferred style and how to more effectively communicate interpersonally and with teams.
Detailed Description: Sustaining a continuous improvement efforts requires defining the company culture and developing team members. The lean philosophy and process must be systematically aligned with the organizations core values in order to seamlessly cultivate a problem solving culture. Lean culture exposes the participants to the systems necessary to prepare lean leaders, to foster the sustained process of continuous improvement and to permeate continuous improvement throughout the organization. The DiSC profile assessment is used for participants to better understand behavioral and communication preferences within themselves and among others.


Hank Czarnecki

Hank Czarnecki serves as director of Auburn University's Technical Assistance Center (ATAC). He has more than 20 years of experience teaching lean, facilitating kaizen improvement events and coaching companies on their lean journey. Czarnecki is Lean Bronze Certified, a NIST qualified lean manufacturing trainer, a Senior Toyata Kata coach and a certified Training Within Industry instructor. He is an AME Southeast Region board member and serves as the ASQ Lean Enterprise Division communications chair. He holds a bachelor's in industrial engeineering from the University of Pittsburgh and a master's in industrial engineering from Auburn University.




  • Understanding of the underlying leadership principles necessary to sustain a lean initiative
  • Ability to practice the Toyota Improvement and Coaching Kata
  • See principles in place with a tour of United Technologies Aerospace
  • Lean practitioners
  • Continuous improvement leaders
  • Senior management

You can become an AME member during the registration process for $150 per year and obtain the discounted AME member rate for this event. Your membership will also entitle you to a registration discount for all future AME conferences, seminars, workshops and webinars for one year. Additionally, you will receive a subscription to the award-winning Target magazine and much more.

Payment or purchase order must be received by the AME office five days prior to the event start date. If no payment or PO number is received, you will be asked to pay with a credit card or check at the event before entry.

Cancellation Policy: Enrollment fee less a $100 non-refundable registration charge will be refunded up to one week before the event. Substitutions may be made up to three days prior to the start of the workshop.

Notes: This event may be canceled by AME for any reason. AME is not responsible for incidental costs incurred by registrants. By registering for this meeting, I hereby acknowledge and agree that AME or its agents may take photographs of me during events and may use those photographs for AME’s purposes, including but not limited to news and promotional purposes, without further compensation to me.