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Lean Six Engineer

Eagle, ID
$3400/week plus normal travel expenses
November 15, 2018

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Robert A. Bailey

Eagle, ID ****6 Cell: 970-***-****


Bob is an innovative integrator of Lean / Six Sigma Problem Solving and Simulation Modeling resulting in decreased time to results and increased client competitiveness.


Independent Management Consultant Nov 2015 – Present

A fabricator of large weldments was experiencing high turnover among welders resulting in lost business. Demand for product was greater than capacity. A simulation model, quantifying all costs of operating with the “revolving door,” was jointly developed with the top management team and the path forward resulted in:

39% reduction in welder turnover

Added $550,000/yr in revenue

A manufacturer of safety equipment needed more capacity on their industrial lasers. Two SMED workshops were conducted with operators and set-up times were reduced by 72%

The same company was using a batch process in a mixed model assembly area and was having a hard time keeping up with demand. A Lean Workshop was conducted with the assembly team and a flow cell was implemented resulting in a Lead Time Reduction of 37%.

A company engaged in re-manufacturing of large industrial bearings needed to increase throughput on one of their major production lines. A VSM along with a simulation model was developed and a simple solution identified. They were able to increase throughput by 61%.

Incito Consulting Group – Business Manager Jul 2014-Nov 2015

On-site Incito Rep at a Kroger manufacturing location. Coached and mentored the Kroger CIL and SME in Total Process Control (TPC) and facilitated DMAIC Kaizen Events consistent with the site Strategic Roadmap.

Trained 56% of the associates of a major Product Line on Lean Principles and Tools

Suggested a design change to a problem pan, which was implemented

oReduced pan damage and increased efficiency resulting in a savings of $6263/month

Designed an alignment fixture for cutters and developed the accompanying procedure as part of a TPM initiative.

oScrapped product was reduced by $3358/month.

Applied Standard Work Combination Sheets on a Quick Changeover Kaizen

oResulted in a savings of $1509/month

MainStream GS, LLC - Senior Management Consultant 2004 – 2007, 2008 - 2014

Lead Consultant, responsible for technical assessments, training teams of mechanics on Principles of Lean and subsequent Lean implementations in USAF weapon system Repair Depots

Reduced Depot Repair Time for a ground attack aircraft by 62%

Reduced Isochronal Inspection and Repair Time on an AF Heavy Lifter Aircraft by 22%

Re-designed the work sequence and reduced the Depot Repair for an AF Heavy Lifter Aircraft by 29%

Re-designed the work sequence for a major AF sub-assembly

oFlow days were reduced by 46%, Overtime reduced by 70%

Conducted a DOE on an Auxiliary Power Unit (APU)

oReduced the failure rate from 50% to almost zero. Yearly savings of $17,000

Designed a Lean Work Cell for APUs increasing thruput by 53% with 37% fewer people

Developed OEE for a complex hard chrome plating operation as part of a TPM initiative.

oDefect rate on the pilot tank dropped from 20% to 0%. Annualized savings $540K

Bob was the Strategic Alignment & Development consultant to the Commander of the 498th Nuclear Systems Wing at Kirtland AFB NM.

Bob worked with the Commander to develop and deploy the FY12-14 Strategic Plan.

oImplemented a WAR Room to track progress on strategic goals with Division Chiefs on a monthly basis.

oHard cost savings from implementation of Better Buying Power $9M

oSavings from more effective allocation of resources $2M

oReduction in travel expenses $1.5M

Clipper Windpower - Supplier Development Leader 2007 – 2008

Responsible for European supply chain improvements related to wind turbine gear sets.

Improved the capacity of the German gear set supplier by 3 times using Lean Techniques.

oThe additional capacity enabled sea shipments resulting in $100,000/week savings in airfreight fees.

The Oliver Wight Companies - Consultant 1991 - 2004

Offered consulting, training, and assessment services in Lean manufacturing and Six Sigma.

Developed and delivered unique simulation training for service and support organizations

Reduced order entry process time for a South American company from 3 hours to 1.7 min.

oDue to the increased responsiveness, orders in Colombia alone increased from 8000/week to 17000/week.

Converted one product family for a capital equipment company from batch to flow.

oCycle time was reduced from 10 days to 2.5 days and $1.5M was removed from inventory.

Implemented a flow process for a large Japanese company building a network switch.

oProcess lead time was reduced from 30 days to 22.5 hours

oInventory was reduced from 300 units to 54 units.

oThe number of operators required in the new process was reduced by 50%.

Hewlett-Packard Company - Engineer/Manager 1976 - 1991

Directed a team, which reduced the cycle-time from software release to first customer shipments from 6 weeks to 3 days.

Developed a class in Designing for Reliability and taught it to hardware engineers.

Developed a reliability growth test known as STRIFE that was adopted by HP worldwide

o HP saved $800M in warranty costs over a ten-year period.

oDesigned the power supply, digital electronics, and performed environmental testing for a dual transport tape peripheral. The entire product was twice as reliable as the single transport sub-assembly in the model it replaced.

Military Service – Capt. USAF/Electronics Engineer 1972 - 1976

Developed the mathematics for a production-line technique used to identify radiation-tolerant semiconductor devices at the wafer level. This capability provided savings by only packaging up ICs that were radiation tolerant.


Master of Science in Electrical Engineering, Colorado State University 1968 – 1969

Bachelor of Electrical Engineering, University of Detroit 1963 – 1968

Additional Specialized Training/Certifications and Affiliations:

Dr. W. Edwards Deming (Quality, Productivity and Competitive Position), Dr. Eliyahu M Goldratt (Theory of Constraints), Dorian Shainin (Six Sigma, Statistical Engineering Series – “Red X”), Du Pont (Strategy of Experimentation), Master Black Belt Certification (Deloitte Consulting). Bob is also a member of the IEEE Computational Intelligence Society.

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