Lean Manufacturing & Continuous Improvement Consultant

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Summary

This Lean Manufacturing & Continuous Improvement Consultant is a transformative manufacturing and operational excellence executive with more than 20 years of experience leading complex turnarounds, Lean enterprise deployments, multi-site manufacturing operations, and organizational restructuring initiatives. He has led operations exceeding $650M in annual sales, $400M in COGS, and workforces of more than 1,200 employees across North America. This Lean Manufacturing & Continuous Improvement Consultant is known for driving measurable operational improvement through disciplined execution, Lean implementation, and organizational alignment, Chris has consistently improved profitability, delivery performance, labor efficiency, quality, and operational scalability within complex manufacturing environments. 

Highlights

• Operational Turnaround & Restructuring 

• Multi-site Manufacturing Leadership 

• Lean Enterprise Deployment 

• P&L and Cost Management 

• Supply Chain Optimization 

• Quality & Safety Leadership 

• Organizational Development 

• ERP & Systems Integration 

• Continuous Improvement 

• Capital Planning & Deployment 

Relevant Accomplishments

• Drove two manufacturing facilities from multimillion-dollar losses to profitability or break-even within 18 months through restructuring, Lean deployment, and operational flow improvements. 

• Reduced labor costs by $6.1M and generated an additional $3.75M in annual savings through procurement optimization and operational cost reduction initiatives. 

• Led Lean Enterprise and Six Sigma initiatives delivering more than $15M in sustained annualized savings. 

• Consolidated six manufacturing facilities into four as part of a multi-year operational restructuring strategy supporting debt restructuring and long-term profitability improvement. 

• Reduced employee turnover by 50% through leadership development, organizational alignment, and workforce engagement initiatives. 

• Improved one facility from a $1.2M loss to a $400K profit within 18 months and another from a $1.5M loss to break-even within one year. 

• Consolidated body and lift gate manufacturing operations from three facilities into one, generating $2M in annual savings. 

• Directed operations encompassing $650M in annual sales, $400M in COGS, and more than 1,200 employees across North America. 

• Managed a $42M operating budget, $4M annual capital deployment, and execution of a $40M factory expansion project. 

• Improved On-Time Delivery from 34% to 85% while reducing overtime from 34% to 21% through team-based problem solving and operational flow improvements. 

• Reduced incident rates by 65% and achieved $600K in workers compensation savings through deployment of standardized safety systems. 

• Generated $900K in annual savings through strategic in-sourcing initiatives supported by targeted capital investment. 
• Achieved 25% in-process defect reduction and 15% output improvement within six months through implementation of structured operational and quality systems.  

Roles

• Independent Operations Consultant 

• Chief Operations Officer, Alcom, LLC 

• EVP Operations – North America,  Palfinger 

• President of Operations USA, Palfinger 

• Director Of Operations,  Toro Company 

• Director of Operations,  Precision Castparts – RathGibson Division 

• Several Operations & Lean Leadership Roles, Oshkosh Corporation 

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