Xtreme Lean Consulting

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Jeff Hofstetter

Jeff Hofstetter

President, Xtreme Lean Consulting


Jeff Hofstetter, President of Xtreme Lean Consulting, has over 24 years of experience in Lean and Six Sigma Consulting. Jeff is a results-driven, decisive leader with a proven track record of initiating time and cost-saving operational improvements while leading diverse teams to strong, sustainable performance gains. Working as a skilled mentor and coach he facilitates a hands-on, positive approach to resource management, leadership development and training.

Experience and skill areas include:

  • Employee training
  • Six Sigma projects
  • Kaizen Facilitator
  • Quality performance improvement
  • Performance measurement systems
  • Problem solving, lean manufacturing
  • Lean business processes
  • Strategic business planning
  • Manufacturing flow
  • 5S visual workplace
  • Value stream mapping
  • Kanban Pull systems
  • Quick tool changeovers
  • Mistake proofing
  • Visual controls
  • Materials and resource management
  • Change leadership
  • Team building
  • Safety
  • Regulatory compliance
  • Project scheduling
  • Process redesign and simplification
  • Technology solutions development
  • Large scale program management
  • NADCAP, ISO and AS quality systems

Jeff holds a B.S. in Business Management and is a Certified Six Sigma Black Belt by General Electric. Also certified by the Supplier Excellence Alliance (SEA) 2007

Marcelo Villacreses

Marcelo Villacreses

Lean Leader / Consultant


Marcelo is with Xtreme Lean Consulting with over 16 years of experience in Lean and Six Sigma Consulting. Marcelo is a leader in the analysis of all operations:

  • Production Processes
  • Supply-chain
  • Inventory Systems
  • Lean Technologies
  • Backlogs
  • Safety
  • Forecasts
  • and Capacity in Manufacturing

Marcelo has created plans of actions that included implementation of strategies addressing all deficiencies, especially closing the gaps to improve operations. The end result was a substantial increase in overall capabilities, quality assurance, and capacity to ensure the achievement of the company plans to increase products, market share and revenues.

Ken Carlson

Business Process Improvement and Lean Techniques Implementation Consultant

Ken’s responsibility is to assist client companies to improve their bottom line by integrating people, processes and technologies to form a company-wide focus to enhance financial results.

Ken is an accomplished senior manager with a proven ability to develop and implement business strategies that eliminate waste and improve the bottom line by utilizing diverse teams from all levels within an organization. Ken is also a respected facilitator able to build highly motivated management and hourly teams focused on achieving revenue and improvement goals.

Ken’s is a high-energy management and engineering professional with exceptional leadership, interpersonal and communication skills with an extensive background in the following assortment of competencies such as:

  • Organization & Operations Analysis
  • Business Process Improvement
  • Supply Chain Management
  • Enterprise Resources Planning
  • Manufacturing Execution
  • Continuous Improvement
  • Creation of Manufacturing Cells
  • Implementing Lean Techniques
  • Aligning Information Systems with Business Processes
  • Systems Selection and Implementation

In addition, Ken is also proficient in:

  • Project Management
  • Time Study
  • Methods Improvement
  • Assembly Line Balancing
  • Plant & Office Layout
  • Process Mapping
  • Manufacturing Process Development

Ken’s talents also include providing customized education, training, independent analysis, coaching, and project management support in all areas of a clients business.

With over 30 years of practical hands on manufacturing experience, Ken has worked with the following industries:

  • Automotive Parts Manufacturing
  • Chain Manufacturing
  • Wire Forms Manufacturing
  • Dairy Equipment Manufacturing
  • Jet Engine Parts Manufacturing
  • Government Subcontracting - Parts Manufacturing
  • Material Handling Equipment Manufacturing
  • Iron Mining
  • Industrial Scale Manufacturing
  • Job Shop -- Steel Fabrication
  • Forest Industry - Equipment Manufacturing
  • Furniture Manufacturing
  • Plastic Molding & Fabrication
  • Telecommunications and Computer Component Manufacturing & Assembly
  • Food Processing
  • Health Care Products Manufacturing
  • Pharmaceutical Products Manufacturing
  • Grey Iron & Investment Foundry Operations
  • Chemical
  • Environmental Science
  • Bio Science and Medical Electronics & Device Manufacturing

Ken received his CPIM Certification from APICS in August 1991 and has served as an Adjunct Instructor @ Winona Technical College - Winona, MN, Red Wing Technical College - Red Wing, MN and Northeast Technical College - Green Bay, WI -- teaching APICS certification courses.

Ken received his Lean Certification – Aerospace Industry - Supplier Excellence Alliance (SEA), Operational Excellence - Facilitator & Trainer August 2007

Ken has also served as: Lean Program Coordinator, Facilitator and Trainer – DePaul University Excellence Consortium, Lean Program Coordinator, Facilitator and Trainer – University of Missouri ST. Louis Excellence Consortium, Lean Program Coordinator, Facilitator and Trainer – Valparaiso University Excellence Consortium

Erika L. Wong

Lean Leader / Consultant

Erika has 14 years of formal Lean & Demand Flow Technology (DFT) implementation & education consulting experience. Deployed Lean & DFT corporate business strategies with major international companies including:

  • American Standard – vitreous china
  • General Electric – aircraft engines, chemical processing
  • Stanley Works – tools
  • Hasbro – toys
  • Case – farming equipment
  • Kohler – plumbing fixtures
  • NACCO – material handling equipment
  • Harman Int’l – audio systems
  • Kellogg’s – cereal processing
  • Kaiser – healthcare
  • Nokia – mobile communication

International experience:

  • Japan
  • China
  • Taiwan
  • Thailand
  • Pakistan
  • Dubai
  • Costa Rica
  • Canada
  • Mexico
  • England
  • USA

8 years six sigma experience – certified MBB
31 years senior manufacturing & supply chain management experience
Education: B.S. Economics – Stanford University


About the author:

Jeff Hofstetter

Jeff Hofstetter Jeff is the President of Xtreme Lean Consulting with over 24 years of experience in Lean and Six Sigma Consulting. Jeff is a results-driven, decisive leader with a proven track record of initiating time and cost-saving operational improvements while leading diverse teams to strong, sustainable performance gains. Skilled mentor and coach with a hands-on, positive approach to resource management, leadership development, and training.


Latest Products

  1. Lean 6 Solutions Greenbelt Training Program

  2. Xtreme Lean Website Video Bundle DVD

  3. Problem Solving for the Workplace 2-Disc DVD Bundle

  1. 5S Video 2-Disc DVD Bundle

  2. Production DVD Bundle

  3. Automation with a Human Touch DVD


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Latest Products

Problem Solving for the Workplace DVD Bundle The problem solving approach taught in this 2 disc presentation is based on the Why Tree Method, and is designed to teach good problem solving skills to people at all levels within your organization.
Production DVD Bundle This 3-disc set focuses on 5S, waste elimination and improving your production. It contains our 3 most popular production DVD's at a discounted price!
5S Series DVD Bundle Our popular 5S Series DVD in both English and Spanish. This 5S Series is a 41 minute long video series produced to ensure the key concepts of 5S are communicated. This video takes the audience through each stage of the 5S process from Sort through Sustain and takes the time to explain how you can improve or implement that stage in your workplace using real life examples.

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