Alcon Labs 
Intermediate level
Value Stream 6 Achieving Business Results

Lean, team-based medical device manufacturing

Wednesday, Oct. 21 Location Code
9:30am-10:30am Room 206/207, 2nd floor WP/24

Implementing product flow in a traditional batch and queue operation

Develop people and improve processes, achieving dramatic performance gains through a lean transformation centered on cultural change; employ lean principles and lean management systems, engaging associates in needed improvements; deploy cross-functional process improvement teams and empower them to make decisions for improving productivity, flow and quality.


Learn how to transform a traditional batch and queue operation with an entitlement culture to an engaged, team-based, continuous flow environment built on the foundation of lean principles and lean management systems. Recognize the power of effective leadership, coaching and communication as you energize and inspire associates in a lean transformation centered on cultural change. Gain insights into the formation of cross-functional process Improvement teams (PITs), empowered with decision-making for enhanced quality, productivity and flow. Learn how teams engaged in kaizen events transform process obstacles into opportunities for improving/developing people and processes. Hear about results engaged, positive people can achieve through systematic, daily improvements, such as a 50 percent inventory reduction, along with a 25 percent decrease in leadtime, 35 percent labor improvement and 50 percent yield increase, while increasing production output 40 percent. These results were achieved during a period when they were crucial to Alcon’s success.


As a global leader in eye care, Alcon develops and manufactures innovative medicines and devices to serve the full life cycle of eye care needs. The company offers a broad spectrum of surgical, pharmaceutical and vision care products to treat many eye diseases and conditions, including cataracts, glaucoma, age-related macular degeneration, retinal diseases, dry eye, eye infection, eye inflammation, ocular allergies, refractive errors and other health issues. Alcon has more than 24,000 associates in 75 countries.

Speaker: David Hurley

David Hurley is the associate director of operations at Alcon Huntington’s AODC-N facility in Lesage, WV.  He oversees an operation of approximately 200 associates who manufacture Monarch® Delivery Systems and the sterilization and packaging of Alcon Huntington’s ophthalmic devices.  He holds a bachelor’s degree in mechanical engineering from the Cork Institute of Technology-Ireland, an M.S. degree in technology management from Marshall University and lean six sigma black belt certification. Hurley has worked for Alcon Research 16 years.