In partnership with Berrien RESA, Bonnell Aluminum is hosting the inaugural Lean 101 Lego Simulation Manufacturing Day Competition, designed to introduce high school seniors to critical manufacturing principles through an interactive, hands-on experience. The event will take place on Thursday, October 9, 2025, from 8 a.m. to 3 p.m. at the Berrien RESA Bertrand Innovation Center in Niles, Michigan. Media is encouraged to attend the event.
Bonnell Aluminum has manufacturing plants in Niles and Elkhart, and several other locations nationally.
The competition, focusing on lean production principles, will feature 18 high school seniors, forming three teams of six participants each, from Brandywine, Buchanan, and Niles High Schools. This initiative aligns with the broader observance of Manufacturing Week, celebrated this year from October 3 through 10.
Participants will engage in the Bonnell Lean 101 Lego Simulation, which uses Lego bricks and a compelling storyline based on the fictional “SnowFUN Company”. Throughout the day, students will learn and apply fundamental Lean Manufacturing philosophies, working to reduce the “7 Wastes” in the industry that hinder efficiency and profitability. The comprehensive competition schedule includes several simulation rounds and focuses on various Kaizen principles, such as Bottleneck Management, Mistake-Proofing and Engineering, and the implementation of 5S, Kanban, and Visual Controls. Students will track key manufacturing metrics like Output, Takt Time, Lead Time, Batch Size, Work In Progress, Total Scrap, Total Finish Goods, Total Rework Goods, Output/Person, and Profit after each simulation round. The rounds will be followed by discussions to analyze their performance and opportunities for improvement.
“We are thrilled to partner with Berrien RESA and our local high schools to provide this unique learning opportunity,” said Daniel Walsh, Technical Training Specialist. “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.”
“The Lean Manufacturing Lego Simulation event represents a collaborative experience where students are not only learning industry principles, but are being coached throughout the competition from leaders in the field,” said Chris Machiniak, Berrien RESA Assistant Superintendent and Regional Director of Career & Technical Education. “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 that they may pursue in the future.”
The event aims to teach valuable lessons, including progression from initial simulations to improved performance, the importance of organization and confidence, and how metric patterns can drive progress. Key takeaways include embracing concepts like “Fail Fast, Succeed Sooner” and “Don’t let perfect get in the way of better”.
At the conclusion of the competition, teams will participate in a debriefing session to discuss their results, focusing on which groups completed their units and achieved the most profit. All participants will receive a Certificate of Achievement for completing the Bonnell Aluminum Lean 101 Training. Team awards will also be presented.
About Bonnell Aluminum: Bonnell Aluminum is a leading manufacturer of custom aluminum extrusions and is committed to fostering education and workforce development in the communities it serves.
