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Matt Zayko

Matt Zayko

President, Zayko Consulting

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
Understanding the 4S Help Chain, Part 2: Lessons from NUMMI on How to Adapt the Model to Product Development
How do you create an andon signal for your product and process development process? Matt Zayko, a technical coach for LEI's Lean Product and Process Development team, explains. More »
Understanding the 4S Help Chain, Part 1: Lessons from NUMMI on How to Manage Work Disruptions
What are the four critical characteristics of an effective help chain? Matt Zayko, a technical coach for LEI's Lean Product and Process Development team, explains. More »
Meeting the 19-Billion-Dose Challenge
What does it take to meet the historic challenge of rapidly increasing the annual global vaccine capacity from 5 billion to 19 billion doses? And how could lean thinking help? More »
How Pall Corporation Accelerated the Covid-19 Vaccine Process Development using Lean Thinking and Practice
Learn how Pall Corp developed and deployed a full manufacturing process in eight weeks – an 80% reduction compared to typical development times. More »
“Too much, Too early” and other Common Pitfalls of Lean Product Development
Veteran product development coaches Eric Ethington and Matt Zayko provide insights about the most common mistakes they see companies make when implementing Lean Product and Process Development (LPPD). More »
Lean Product and Process Development Learning Group Update: Technical Organizations Share Common Practices to Spread the Learning
Lean Product and Process Development Learning Group Update: Technical Organizations Share  Common Practices to  Spread the Learning  More »
Lean Product and Process Development Group Update: Leading Companies Share and Learn from Common Challenges
The Lean Enterprise Institute recently organized a meeting of the Lean Product and Process Development Learning Group that brought together the diverse industries of sub-sea robotics, appliances, consumer electronics, automotive research, contemporary furniture, and drilling equipment. More »
How Does Shop-Floor Lean Compare to Lean Product and Process Development (LPPD)? A Q&A with Matt Zayko
Matt Zayko was recently asked, "Is my knowledge of shop-floor lean enough for me to get by in product development?" Find out his answer. More »
Innovative Companies Continue to Learn from Each Other: Fall 2016 LPPD Learning Group Event
Find out what learnings took place at the Fall 2016 LPPD Partners' Meeting in Davis, California. More »
Why Creating Products Customers Actually Want Requires a Great Process
80% of the cost (and hence, waste) is committed for a new product or service by the time product designs get locked-in during development. Still, most PD leaders focus their improvement efforts where 80% of cost is incurred—the operational value stream, post-launch. Learn why your focus should be on lean process design. More »
Lean Transformation: Thinking, Learning, & Experimenting For Today’s Complicated Operating System
Matt Zayko, an LEI faculty member, notes that many organizations that have tried to implement lean in the past 20 years have fallen short. To succeed, he recommends that you answer four key questions:What is the performance problem you are trying to solve?What are you doing to simplify your operating system activities?What are your organization’s improvement capabilities?What is your improvement approach? More »
Workshops Taught by Matt Zayko
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 »