Lean Continuous Improvement and Value Stream Leader

TYRONE WASHINGTON

Moncks Corner, SC 864-***-**** *******************@*****.***

CONTINUOUS IMPROVEMENT MANAGEMENT ENGINEERING LEADERSHIP PROFESSIONAL PROFILE

Continuous improvement and engineering leader with 25+ years of experience in Lean manufacturing, multi-site operations, and leadership development. Led initiatives contributing to $109 million+ in cost avoidance and savings. Translates business strategy into process improvements and workforce development programs that strengthen quality, productivity, and employee engagement.

CORE COMPETENCIES

• Continuous Improvement and Operational Excellence

• Engineering and Manufacturing Leadership

• Lean Manufacturing Systems

• Strategic Planning and Organizational Development

• Root Cause and Corrective Action (RCCA)

• Kaizen, Gemba, and Hoshin Kanri

• Value Stream Mapping and Waste Reduction

• DMAIC, A3, and 5 Whys

• Total Productive Maintenance and SMED

• KPI Development and Performance Management

• Standard Work and SOP Development

• Leadership Training and Talent Development

• Change Management and Employee Engagement

• Multi-Site Operations and Cross-Functional Leadership

• Cost Reduction and Resource Optimization

• Time and Motion Studies

• Quality, Safety, Delivery, Cost, and Morale

• Project Management and Technical Training

PROFESSIONAL EXPERIENCE

Owner / Independent Consultant January 2024 – Present Stroke of Genius Transformation Group

• Training Development: Deliver training and engagement programs strengthening learning, mental awareness, and mobility for individuals, teams, and workforce partners.

• Technology Integration: Identify assistive technologies and learning strategies supporting accessibility and participation for individuals with physical disabilities.

• Program Design: Create technology-integrated courseware for manufacturing, residential, corporate, and medical partners.

• Cost Optimization: Develop cost-control tools supporting an 85% monthly savings target aligned with organizational and stakeholder goals.

Chief Transformation Officer / Independent Consultant January 2022 – Present TJW Leadership Solutions

• Continuous Improvement: Lead Kaizen, Value Stream Mapping, Gemba, and 6S initiatives improving Lean manufacturing, workflow, and organizational effectiveness.

• Leadership Development: Train managers and executives in employee engagement, team development, and Lean leadership.

• Performance Management: Evaluate team-building metrics and establish indicators supporting employee development and organizational growth.

• Training Architecture: Develop continuous improvement courseware, study guides, and facilitator programs addressing skill gaps, bottlenecks, and downtime.

• Employee Retention: Teach engagement and communication practices to reduce attrition, strengthen retention, and support advancement.

• Operational Compliance: Deliver instruction on quality, production, safety, and environmental, health, and safety requirements.

Continuous Improvement Manager June 2021 – October 2021 Aalberts / Apollo Valves IPS Pageland, SC

• Lean Implementation: Introduced continuous improvement and structured problem-solving methods to strengthen employee participation and operations.

• Process Standardization: Standardized manufacturing Statements of Work across two sites to align practices and improve consistency.

• Quality Improvement: Developed strategies targeting 50% fewer nonconformances while addressing shop- floor waste, machining capability, and tooling repeatability.

• Cross-Functional Leadership: Led Gemba walks, Kaizen events, and improvements in material movement, logistics, and assembly.

• Daily Management: Restructured tiered meetings to improve communication, priorities, and daily and weekly workload planning.

• Organizational Development: Facilitated town halls, surveys, and leadership training to assess workplace needs and strengthen accountability.

Water Spider December 2020 – July 2021

Amazon CAE1 West Columbia, SC

• Production Support: Moved assembled books, unfinished sections, and paper supplies to printing, binding, and packing lines to maintain flow.

• Material Availability: Replenished totes and materials supporting assembly capacity and equipment setups.

• Safety Improvement: Supported safety leadership with corrective actions and continuous improvement recommendations.

• Process Improvement: Partnered with process engineers to improve equipment setups and production workflows.

Inbound Dock Technician Internal Transfer from CAE1 Amazon CLT3 Concord, NC

• Inbound Operations: Routed received goods to downstream teams and supported loading for customer delivery.

• Shipment Accuracy: Used handheld scanners to identify, sort, and route shipping bundles.

• Workflow Improvement: Identified improvements in receiving processes and material movement. Client Robotic Warehouse Technician, Contract October 2019 – March 2020 XPO Logistics Greensboro, NC

• Robotic Systems Testing: Supported robotic warehouse system testing and development for logistics and transportation.

• Process Auditing: Developed audits assessing robotic performance, process gaps, and quality improvement opportunities.

• Standard Work: Created Standard Operating Procedures and work instructions for supply chain personnel.

• Root Cause Analysis: Troubleshot systems and evaluated performance metrics to support Root Cause Corrective Action.

• Cross-Functional Collaboration: Partnered with directors, technical associates, and engineers to improve systems and supply chain flow.

Global Product Engineer Leader, Contract TSG April 2019 – November 2019 Tempur + Sealy Trinity, NC

• Manufacturing Improvement: Partnered with Global Product Engineering teams on continuous improvement in manufacturing and product development.

• Quality Auditing: Developed calcium carbonate foam-testing audits, coordinated plant audits, revised SOPs, and applied DMAIC to address measurement variation.

• Packaging Optimization: Improved mattress packaging and technician training for handling, testing, shipping, and Amazon packaging certification.

• Data Analysis: Audited 7,500+ component records to identify redundancy and improve data consistency.

• Capital Equipment: Evaluated LPX+ equipment relocation, installation, and calibration for tensile testing.

• Corrective Action: Analyzed recurring errors and developed process recommendations, designs, and training addressing defects and downtime.

Site Leader of Employee Operations / Lean Process Manufacturing 2014 – April 2017 Boeing South Carolina Charleston, SC

• Operational Leadership: Delivered Lean manufacturing and workforce development strategies for 350+ teams supporting 7,500+ employees.

• Cost Improvement: Led employee involvement and process improvements contributing to $109 million+ in cost avoidance and savings.

• Leadership Development: Coordinated site training through 23 coaches and managers; standardized engagement and Lean learning tools.

• Strategic Execution: Partnered with leadership and cross-functional teams on organizational development, accountability, and continuous improvement.

Manufacturing Employee Involvement Team Leader 2013 – 2014 Boeing South Carolina Charleston, SC

• Management Development: Created quarterly executive training and monthly programs for team leaders and first-line managers.

• Employee Engagement: Strengthened manufacturing and management collaboration; aligned development with workforce planning and performance goals.

Site Project Manager / Senior Engineer, Manufacturing Engineering 2007 – 2013 Boeing South Carolina Charleston, SC

• Engineering Leadership: Directed manufacturing engineering, tooling, maintenance, production integration, repair, and rework initiatives.

• Training Development: Created Manufacturing Engineering University and led technical experts in instruction, mentoring, and curriculum development.

• Financial Performance: Generated $5 million+ in budget savings and $15 million through supplier negotiations.

• Procurement Management: Negotiated with 25 international vendors, saving $1 million+ per manufacturing business unit per quarter.

• Learning Optimization: Reduced training costs 75%, generating approximately $9 million in annual savings. PRIOR EXPERIENCE

Additional Engineering & Leadership Experience

Plymouth Tube Company Triumph Aerostructures TJW Leadership Solutions Vought Aerospace General Electric

• Engineering Management: Led multisite engineering, maintenance, and tooling teams at Plymouth Tube, with initiatives targeting $2 million in cost reductions.

• Production Improvement: Identified 394+ actionable production issues and directed 10 industrial engineers in assembly time studies at Triumph Aerostructures.

• Leadership & Manufacturing Support: Delivered executive training through TJW Leadership Solutions; supported production planning, material allocation, and equipment improvement in earlier roles. EDUCATION

Doctorate in Organizational Leadership

Granttown University Online 2013

Master of Business Administration — Engineering and Project Management Granttown University Online 2012

Bachelor of Arts in Christian Ministry

Carolina Theological Bible Institute 1999

Mechanical Engineering Coursework

South Carolina State University and North Carolina A&T 1988–1993 PROFESSIONAL DEVELOPMENT

• Executive Education Certificate, Project Management — University of South Carolina, 2017

• Executive Education Certificate, Leadership Excellence — University of South Carolina, 2017

• Executive Education Certificate, Leveraging Leadership — University of North Carolina at Charlotte, 2016

• Training in Six Sigma and Green Belt Processes

COMMUNITY LEADERSHIP

Chosen Life CEO / Operations General Manager 1996–Present

• Lead nonprofit organizational planning, recruitment, leadership development, budget allocation, and community enrichment programs.

• Deliver motivational presentations and individual coaching while developing leaders to execute organizational goals.

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