Matt Zayko

Matt Zayko has twenty-five years of experience in leading lean enterprise improvements in numerous industries by helping people transform product development, engineering, manufacturing, service processes, and operating systems.  Matt worked in a variety of staff- and management-level roles under the guidance of former Toyota mentors for Chrysler / University of Michigan, Gelman Sciences, Delphi, and Pall (now part of Danaher) before starting his own consultancy and affiliating with the Lean Enterprise Institute (LEI). 

Matt has authored numerous works based on successful transformation, including articles that have been published in “Journal of Quality Engineering”, “IIE Solutions”, and “Journal of Cost Management”, plus a chapter in the 1998 Shingo-Prize winning book “Becoming Lean”, and many white papers for the Lean Enterprise Institute. Matt is a frequent presenter at conferences related to lean transformation and a long-time faculty member of LEI as well as a coach in LEI’s Lean Product and Process Development (LPPD) initiative, working closely with smaller, entrepreneurial-minded organizations, as well as larger, global companies.

Matt received his M.S. in Industrial & Operations Engineering from the University of Michigan at Ann Arbor. 

Articles by Matt Zayko

Lean Product and Process Development Group Update: Leading Companies Share and Learn from Common Challenges

How Does Shop-Floor Lean Compare to Lean Product and Process Development (LPPD)? A Q&A with Matt Zayko

Innovative Companies Continue to Learn from Each Other: Fall 2016 LPPD Learning Group Event

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Workshops Taught by Matt Zayko

Lean Process Creation: Why Developing a Product that Customers Actually Want Requires a Great Process to Produce and Deliver It (at the 2019 Designing the Future Summit) Lean Process Creation: Why Developing a Product that Customers Actually Want Requires a Great Process to Produce and Deliver ItMany leaders focus the majority of their process improvement efforts after the launch of new products or services. But by then, nearly 80% of the cost -- and hence waste -- has already been locked-in by the product and process designs.  In contrast to traditional methods of creating new products and services, Lean Product and Process Development (LPPD) is about creating profitable value streams. This includes designing all of the process steps required to build and deliver your product or service More »

Value-Stream Mapping for Manufacturing Learn how to use this fundamental initial step in a lean transformation to create the "blueprints" for applying other tools and targeting kaizen events most effectively. More »

Value-Stream Mapping for Manufacturing: Gemba-Based Workshop This workshop, now offered live for the first time, shows you how to create and apply this fundamental and critical tool, based on Lean Enterprise Institute's groundbreaking VSM workbook, Learning to See, which has introduced the mapping tool to thousands around the world More »