Sustaining Lean-Sigma Results and Culture

April 11, 2012
RIT Inn and Conference Center
5257 W. Henrietta Rd.
Rochester, N.Y. (near I-90 exit 46)

The Rochester Chapter of the Institute of Industrial Engineers presents a one-day conference for lean-sigma practitioners, engineers and managers.

At your organization:

  • What percent of your lean Six Sigma results last beyond six weeks? Three months?
  • How many of your rapid improvement/kaizen events have to be "redone?"
  • Do your lean process metrics look good while your results metrics stay the same or look worse?

At this conference you will learn:

  • A methodology for analyzing standard work behaviors that do not sustain.
  • A methodology for sustaining new processes and gains: process behavior maintenance.
  • A methodology to focus “soft” skills in a way that yields lasting “hard” results.

You will leave this conference with:

  • Analysis tools to diagnose high variability/low sustainability in standard work.
  • A tool for maintaining new process behaviors (a.k.a. new standard work).
  • Gain-sustaining methods to add to your control plan and/or leader standard work.


Michael McCarthy

Michael McCarthy is the author of Sustain Your Gains: The People Side of Lean-Six Sigma. He is an experienced Lean facilitator, performance improvement consultant, and corporate trainer. While at Accenture and Aubrey Daniels International, he consulted with Eastman Kodak, 3M, and Black and Decker. He edited Performance Management Magazine and co-authored You Made My Day, addressing process improvement and positive work culture.

R.I.T. Professor of Industrial and Systems Engineering John Kaemmerlen wrote: "'Sustain Your Gains' offers very specific descriptions of how to help people practice lean behaviors that will work in their organization, and continue practicing those behaviors, so the results gained from lean implementation continue on."

Mike asks that participants at the 1:15 p.m. workshop bring examples of their "gain sustaining" issues.

Michael Hansen

Michael Hansen is the quality and lean systems manager for Warren Distribution. He has led Warren Distribution’s lean efforts for the past eight years. Michael has responsibility for the lean acculturation of Warren associates. Michael’s previous work history includes a career as a software engineer and as a high school teacher and coach.

Michael will speak on "Lean Reinvigoration." He will explain the journey at Warren Distribution to a culture that sustains Lean, including:

  • The 1999 start: quick and dramatic reductions in waste and inventory, but not all sustained.
  • A "Lean Reinvigoration" in 2008 implemented an annual lean diagnostic scorecard, leader standard work, tiered morning huddles, and experimentation with TWI.
  • A "cave man simple" way to implement and sell leader standard work in your organization.

Conference Agenda – APRIL 11, 2012

  • 9:30 – 9:45 a.m., Opening comments – John Kaemmerlen
  • 9:45 – 10:45 a.m., "Lean Reinvigoration" – Michael Hansen
  • 11:00 – 12:00 p.m., "Sustain Your Gains Overview" – Mike McCarthy
  • 12:00 – 1:15 p.m., Lunch & networking
  • 1:15 – 4:15 p.m., Workshop: Sustain Lean Gains Methodology – Mike McCarthy
  • 4:15 – 4:20 p.m., Close

Registration Fee*:

  • $129 for IIE members
  • $179 for non-members
  • $45 for IIE student members
  • $65 for non-member students

*Quantity and early bird discounts available.

To register, email John Kaemmerlen at or call (585) 475-2767.

Registration closes Friday, March 23.

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