by Dave Rizzardo
Our second MWCC Lean Facility Tour of 2025 took us to the Lonza facility in Walkersville, Maryland. It was an insightful and educational morning as we learned about their Lean Business Management System (LBMS), which began deployment in 2022. Following an engaging presentation, we toured the facility to see firsthand how the LBMS is applied in daily operations.
What sets Lonza apart is the depth of commitment and engagement throughout the organization in their enterprise-wide Lean transformation. Their Walkersville location has been selected as a best practice model (lighthouse) to guide deployment efforts across Lonza’s global facilities—a testament to their success. In any Lean transformation, the word "journey" is often heard, and it’s clear that Lonza is excelling on every critical front. Their strong foundation, anchored by "Lean Leadership," ensures a sustained focus on continuous improvement and a culture of operational excellence.
During the tour, we observed solid 5S practices and learned about the systems in place to sustain them. One standout feature was their tiered huddle process, which ensures daily communication from the plant floor to upper management and aligns priorities across all levels. The LBMS effectively addresses both cross-functional strategic issues and plant-floor Kaizen activities—proving that small, localized improvements can be just as impactful as broader initiatives. Other highlights included their emphasis on Gemba Walks and their advanced digitization efforts, such as an innovative idea system that encourages continuous innovation.
We concluded the morning with a tour debrief, where attendees shared positive Lean takeaways and offered thoughtful suggestions for the Lonza team. The day wrapped up with lunch and networking—fueling both our bodies and our ongoing Lean learning.
A huge thank you to all who attended, and especially to our gracious hosts at Lonza for sharing key aspects of their Lean journey through the lens of their LBMS. It was truly a Lean-filled morning of inspiration and learning!
