Biography for Michael Hogan

Michael Hogan is a consultant with over 28 years experience in operations management and continuous improvement. He studied and applied Lean manufacturing and Six Sigma methodologies at Burgess Norton Manufacturing where he worked for over 22 years. Burgess Norton Mfg. provided the opportunity to learn from the gurus of Lean such as Charlie Protzman, SME, Maryland World Class Consortium, and Johnson & Johnson.

He has held operations leadership positions such as Director of Operations, Plant Manager, and Director of Continuous Improvement. Mike has taught improvement techniques and helped many other companies along their journey to becoming a world class companies.

Mike’s experience in implementing Lean Manufacturing covers a number of manufacturing industries including: foundry processes, machining, sheet metal fabrication, grinding, high and low volume assembly, electro-static painting. In healthcare Mike has applied lean principles to nutritional services, laboratories, surgical departments, emergency departments, registration processes, radiology, and other hospital service areas.

Mike is an expert in value stream mapping techniques for healthcare and manufacturing processes. He has applied both Six Sigma and Lean techniques to a broad range of business processes including Procurement, After-market Customer Service, Hospital Laboratory and Emergency Departments. Machining, Grinding, Sheet Metal Fabrication, Stamping, Paint (both wet and powder coatings), and other processes. Mike has worked with production volumes that have ranged from low volume/high mix to high volume (34,000/day) lines. Some of the results he has achieved include:

• Used Kanban, Supplier Managed Inventory, and Back-flushing of parts to reduce inventory at Honeywell Aerospace, reducing one department’s backlog from over 5,000 hours behind to less than 100 hours monthly.
• Implemented work cells in healthcare nutritional setting with an 80% improvement in efficiency.
• Saved $13 million in capital through Lean Design in a nutritional department.
• Applied cellular principles to numerous labs.
• Applied lean design to hospital renovations and new builds, including lab redesign, surgical redesign, new construction including LeBonheur Children’s hospital, and Florida Hospital new tower addition. 
• Applied Lean Tools to edibles express which achieved a 58% reduction in required labor.
• Applied SMED (setup reduction) in multiple plants resulting in an average of 50% reduced setup time.
• Implemented Standard Work techniques resulting in an 82% reduction in customer backlog over a 4 week period.
• 50% reduction in processing time for corrective action process and sales forecasting methods.
• Through lean improved ED doctor’s productivity by 43%, reduce left without being seen from 12% to 3%.
• Introduce Hoshin Planning (management by Plan) to senior staff.
• Value Stream Mapping in a variety of healthcare & manufacturing applications.
• Experienced in the Toyota Production System, based on the teachings of Shingo, Taylor, and Gilbreadth.
• Compiled a 5-day, 3-day, 1-Day, and similar interactive training courses. Some training has been translated into Spanish.

Mike has a BA in Industrial Psychology and Business from the University of St. Francis. He is a certified Lean Master from the Maryland World Class Consortium and the Business Improvement Group. Mike is a Green Belt Six Sigma and is certified in Myer-Briggs Personality Assessments.

Mike has trained over 3,500 people from all over the world including Belgium, France, and Germany in lean and total quality techniques. Mike started his own company, Progressive Business Solutions in 2003. Progressive Business Solutions works hand in hand with companies to improve productivity, cost reduction, delivery, and quality. Techniques include Value Stream Mapping, Five S, Visual Controls, Setup Reduction, Kanbans, Lean Design, Poka Yoke, Standard Work, Capacity Analysis, Hoshin Kanri (Management by Plan), and Utilization.