Lean Operations


A Series of Interactive Exercises Demonstrating Lean Benefits

Instructor: Michael D. Ford
Date: Saturday, February 29, 2020
Time: 9:00 a.m. - 4:00 p.m. (Morning snack and lunch provided)
Location: Innovative Technologies Complex (ITC), ES 2008, Binghamton University, 85 Murray Hill Rd, Vestal, NY 13850 
Credentials: You will earn a Micro-credential in Lean Operations and receive the Lean Foundations digital badge if you complete the course by passing the course assignment at the end of the day. A Certificate of Course Completion will be issued to all course participants.

The course is approved for 0.6 Continuing Education Units (6 contact hours).

Who can take this course: This workshop is open to all engineers, professionals and students.



This full day “play shop” stimulates the audience through a variety of hands-on exercises that engage participants in role-play simulations that are guaranteed to provide valuable lessons learned. The audience will observe, appreciate, and understand lean benefits. Most importantly, they will REMEMBER these years later, a key to providing attendees with more than theory: they will be able to APPLY the concepts at work.

The workshop facilitator uses a hybrid approach that includes: team and individual exercises; physical, mental and social activity; role play simulations; group discussion; Q&A; and just a smidgen of lecture. This approach will maximize the potential across a wide array of modalities: left and right brain; visual-auditory-read/write-kinesthetic (VARK) positions; and both active and passive learners.

The following exercises will utilize simple props such as cards, dice, play money, bingo chips, Legos, potato chips, rope and blindfolds (YIKES!). Attendees are certain to have fun, which enhances the learning experience.

  • Strategic Planning: What are the Necessary Ingredients?
  • Kanban Simulation: How do Pull Systems Work?
  • Lot Size Reduction: What Improvements Result From Small Lots?
  • Volume/Variety Matrix: What Contrasts Exist Among ETO-MTO-ATO-MTS?
  • Variability Reduction: What Improvements Result From Process Consistency?
  • Heijunka Scheduling: How Does Level Loading Facilitate Production Planning?
  • Product Structure Assessment: How do Flat BOM’s Improve Planning?
  • Lean Design: What Product Features Add Value?


  • “Ice-breaker” exercises will kick off the day and after breaks to re-energize the audience.
  • Feedback mechanisms are employed throughout the day for continuous improvements on the fly.


Michael D. Ford, M.S.I.S.E., CFPIM, CSCP, CLTD, CQA, CRE, CQE, ACPF, CPSM, CSSGB is a Supply Chain Expert with TQM Works Consulting. He provides innovative solutions, based on 30 years of experience in retail, distribution, manufacturing, and consulting.  His work history includes software implementation, business planning, inventory control, distribution planning, and corporate training.  This includes a broad range of experience from ETO (Engineer to Order) to MTS (Make to Stock), as well as non-profits, service, and Department of Defense.

He has presented at over 350 industry events throughout the U.S., Canada, Japan, Nigeria, S. Africa and Australia, and has provided over 5,000 hours of classroom training, averaging 4.5/5.0 on evaluations.

Ford combines his technical expertise with personal skills, to develop a unique “outside the box” approach to life’s challenges.  He is a charismatic speaker who specializes in delivering training that is “edu-taining.”


$295: Standard/Industry Rate (Group rates available, see below)
$250: NYSSPE or ASQ members
$195: BU and SUNY faculty/staff/Alumni (Graduated May 2020 or earlier)
$105: Non-BU and non-SUNY students (must give evidence of matriculation at University/College, please email wtsnindy@binghamton.edu)
$95: BU and SUNY Studnets and recent BU Alumni (Graduated December 2020 or later)/High School Students

Group rate for industry available (2-4 participants, 5-9 participants, 10 and up)

For group rates contact the Office of Industrial Outreach at:
Phone: 607-777-6241or wtsnindy@binghamton.edu


All cancellations must be received in writing by 5 pm Thursday, February 27 to receive a refund. No refunds for cancellations or non-attendance will be given after 5 pm on that date.

Substitutions may be made any time before a certain date by informing the Office of Industrial Outreach.

A $20 refund fee will be applied

If the course is canceled, enrollees will be advised and receive a full refund.