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Manager Process Improvement

West Linn, OR
February 29, 2016

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Robert Shaw

***** ******* **. ****** ****, OR ***45

Home: 503-***-**** Cell: 503-***-****


Enthusiastic, dynamic, servant leader with over 20 years of expertise in continuous process improvement, problem solving, and cultural transformation. Energetic, innovative instructor, coach and motivator with a proven history of sustained superior performance. Highly skilled in the areas of:

Lean Manufacturing/Lean Six Sigma Curriculum Development and Maintenance

Cultural Transformation Technical Training

Process Improvement Coaching and Mentoring

Root Cause Analysis Facilitation


XPO Logistics, formerly Con-way Corporate Enterprise Services (CES) 2011 – 2016 Lean Sensei

Responsible for teaching, coaching and utilizing lean techniques for process improvement, problem resolution and cultural transformation throughout the CES campus. Specific techniques include: Lean Production System, Flow, Pull and Takt, KanBan, 5S, Scientific Method (A3), Standardize Work, Visual Management, Servant Leadership, Coaching Kata, Hoshin Kanri, Leaders Standard Work and Value Stream Mapping.

Oversaw the completion of over 250 Lean transformation activities at the CES campus, resultng in over $6 million in cost reduction.

Developed and implemented the Lean Manager Certification focused on cultural transformation and leadership behavior. To date, 50% of managers have entered the program, with 35% certifications issued.

Developed and implemented the Lean Coach Certification focused on technical and interpersonal skills. To date, 50% of all coach candidates (30) entered have been certified and provide technical expertise to leadership and improvement teams throughout the organization.

Initiated improvement efforts at the trailer manufacturing facility. Certified two lean coaches and established shop floor initiatives, 5S and visual management resulting in a 10% improvement in production.

Coached lean activities and cultural transformation for IT and Administration functions in the Asia operating areas. Four lean coaches have been certified with five managers in process for certification.

Mainstream Global Solutions LLC 2004 – 2011

Senior Lean Consultant

Oversaw all lean activities for multiple Air Force Commands, ensuring all efforts yield measureable results, are sustained and in alignment with organization strategy. Managed and facilitated Value Stream identification, development and improvement, utilizing KAIZEN and business process improvement methodologies.

Air Mobility Command

Developed and implemented a lean organization utilizing lean leadership to transform the culture and by establishing the use of strategy deployment to plan and execute process improvement.

Defined and implement metrics at all levels of the organization. Effected cultural transformation through then use of lean leadership.

Directed and mentored senior leadership and developed standard processes for certification of facilitators, training of wing personnel, standard work for the work up and conduct of improvement activities.

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Developed point of use tool checkout and inventory system for aircraft mechanics, resulting in a yearly net of $3.8 million in productivity.

Reduced aircraft regeneration time by 35% resulting in a $20 million annual savings in operating costs.

Utilized manufacturing methods in an administrative process to improve processing of travel vouchers. Implemented one piece flow and mistake proofing to reduce lead time by 90% and defects from 56% to 4.9%.

Improved military identification card process, reducing total processing time from 3 hours and 45 minutes to 15 minutes.

Conducted advanced training to leadership, supervision and flight line personnel in the following areas:

o Technical skills: Value Stream mapping, TAKT time and cycle time, cell design, Kanban, 5S, JIT, Jidoka, time observations, spaghetti diagrams. o Cultural skills: Johari window, PA/PT, Situational leadership, Value systems, Lean acceleration, Strategy deployment, Myers/Briggs type indicator (MBTI), Leadership, coaching, scientific method, PDCA..

Air Force Materiel Command

Conducted Value Stream based lean event for 20mm gun systems for fighter aircraft, resulting in reduced cycle time from 365 days to 60 days, reduced travel distance from 46 miles to 8.5 miles and reduced floor space by 30%.

Developed product families for Hydraulic/Pneumatic workloads (793 separate items). Developed current and future state value stream maps for each product aligned by process route. Freightliner LLC, Portland, OR 1998 – 2002

KAIZEN Office and Program Manager

Established, implemented and sustained the process improvement program (KAIZEN). Developed and presented the training and qualification program for KAIZEN and instructional staff. Managed personnel.

Supervised 102 KAIZEN events in a three year period, resulting in an average of 20% improvement in productivity, 56% reduction in Work in Process (WIP), 33% reduction of required floor space, 30% reduction in operator cycle time and 48% reduction in worker travel distance per event.

Reduced the processing time of damaged materials from three weeks to 72 hours reducing the amount of pending materials by $823,000.

Developed process to identify and prevent coolant leaks. Coolant leak warranty claims dropped from number two to number twenty two.

Performed Employee orientation for over 1000 people ensuring a smooth transition of personnel into the production staff.

Developed multimedia presentations for assembly of Heavy Duty Trucks, ensuring a uniformly high product quality.

United States Navy 1976 – 1998

Master Instructor, Curriculum Manager and Developer, Program Manager Senior Enlisted Leader and Certified U.S. Navy Master Training Specialist. Expert in areas of instructional delivery, curriculum development and maintenance, student management and instructor evaluation. Certification is awarded to the top five per cent of all Navy instructors.

Developed and implemented a multimedia training program which included lectures and seminars, audio taped presentations, on the job training and computerized simulations improving individual knowledge level as well as team skills.

Managed senior staff instructors providing guidance and motivation.

Developed and implemented qualification programs for instructors and provided individual training focusing on improvement of classroom skills.

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Bachelor of Science degree in Multidisciplinary Studies Grantham University, Lenexa KS

Magna Cum Laude


Lean and Cultural Transformation Seminars – Association for Manufacturing Excellence Lean Seminars – Northwest High Performance Enterprise Consortium Lean Training – Time Based Management through Freightliner Six Sigma Training – United States Navy

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