On October 9, as part of Manufacturing Week, Bonnell Aluminum and Berrien RESA will host the inaugural Lean 101 LEGO Simulation Manufacturing Day Competition. Students from Brandywine, Buchanan, and Niles High Schools will compete in an immersive, hands-on simulation — producing snowmobiles for the fictional “SnowFUN Company.” Their challenge: apply real-world lean manufacturing principles to improve productivity while cutting waste.
The competition introduces students to concepts such as bottleneck management, mistake-proofing, and the use of 5S, Kanban, and visual controls. Participants will track metrics like takt time, lead time, batch size, work in progress, scrap levels, and rework rates. Each round of the competition will bring fresh opportunities to rethink processes — and demonstrate how efficiency can be taught through play.
“This simulation is designed to give students practical insight into manufacturing processes, problem-solving, and continuous improvement, fostering skills that are vital for future careers in our industry,” said Daniel Walsh, Technical Training Specialist at Bonnell Aluminum.
Chris Machiniak, Berrien RESA Assistant Superintendent, sees the value as extending far beyond the competition. “By bringing opportunities like this directly to our high schoolers, they can enjoy a hands-on approach to sharpen their skills while learning about a career they may pursue in the future,” he said.
At the end of the day, teams will present their results, receive certificates, and perhaps leave with more than just recognition. Bonnell Aluminum and Berrien RESA aim to inspire curiosity, bridge the gap between education and industry, and sow seeds for the next generation of manufacturing talent.
