TWI Network
2121 Rawsonville Rd.
Belleville, MI 48111
TEL: (734)484-4788
FAX: (734)484-4785


Michael Husar

Mike is an acknowledged leader in the area of lean manufacturing technology and implementation.  As a well known “change agent” in the automotive industry, he specializes in improving an organization’s ability to reduce costs through systemic changes in product, process and management style.  Mike has been involved with a wide range of companies including General Motors, Delphi, Toyota, Harley-Davidson, Plastic Omnium, Lockheed Martin Aerospace, Blue Cross Blue Shield Healthcare, Siemens and the Tech Group. His accomplishments were also reported in the New York Times in addition to inclusion in a chapter in the book “Becoming Lean” by John Liker, Productivity Press 1997.

Selected Accomplishments
Responsible for global implementation of lean manufacturing for a tier one automotive supplier involving 20 manufacturing plants located in 11 countries that reduced costs by over 5% per year.

Led the restructuring of a large, unionized automotive supplier manufacturing plant (2200+ employees) that became recognized both as a 1999 Industry Week Top 10 Plant and a 2000 Year Shingo Best Plant; plant profitability improved by over $13 million per year.

Responsible for manufacturing operations (6 plants, 8000+ employees) for a division of a large automotive supplier; reduced manufacturing costs by over $100 million.

Led the manufacturing engineering for new lean processes for a new product line deployed in Europe, China, Korea, and North and South America for a major automotive supplier.

Developed and implemented cost reduction ideas for a major automobile manufacturer that reduced vehicle unit cost by $3.

Led the integration of several problem solving technologies (six sigma, Shanin, Taguchi, etc.) into a common, comprehensive process for a large tier 1 automotive supplier; subsequent deployment delivered documented savings of over $20 million for the first year of the initiative.

Led the development of a process to standardize how manufacturing engineering does its work in selecting the “right” lean manufacturing process to use to execute product designs at lowest cost, highest quality as well as meet production start-up targets.

Trained over 75 key engineering leaders in lean manufacturing concepts for a large automotive supplier.

Played a lead role in a major automotive supplier’s labor contract negotiations resulting in significant work rule relaxations, classifications, and improved union-management relations.

Led the introduction and implantation at a large automotive supplier’s division of the following key lean manufacturing system components:  standardized work, customer focused production cells, level scheduling, lean tooling/equipment concepts, error proofing, andon systems, 5 S and production work teams.

Educational Background

MBA, Baldwin-Wallace College
MS, Systems Engineering, Case Institute of Technology
BS, Mechanical Engineering, General Motors Institute


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Telephone:                 810-348-2712