Bob Fesler - USN Veteran, MBA, PMP, LSS-BB (9K LION)

Experience

• 

  US Navy

  Sept 1972 - Aug 1977

  Lieutenant, Civil Engineer Corps, USN

  1975 - 1977 - US Naval Air Station Sigonella, Sicily, IT• Reduced dramatic utility failures for on-base housing and aircraft maintenance by 35% in 24 months through systematic preventive and predictive maintenance methodologies• Reduced excess, obsolete & redundant equipment that drained maintenance and repair budget by 85% in first 12 months• Surface transportation assets were 30% under allowance and with Theatre and Corps assistance in last 24 months this rose to within 5% of established allowances1972 - 1975 - US Naval Mobile Construction Battalion - FIVE, Port Hueneme, CA• Responsible for a maintenance and repair budget in excess of $2MM and 100 local civilians and US Seabees performing all utility, transportation and facility maintenance activities.• Company commander responsible for 45-65 Seabees of various ratings during 9-month deployments to Okinawa, JP, Roosevelt Roads, Puerto Rico & USMC Vieques Camp, PR accomplishing training, maintenance and operational assignments on-time, on-budget, and with zero safety incidents• Improved retention rate from 15% to 25% of subordinates on first re-enlistments during Sicily duty station Show less

• 

  Burlington Industries, Greensboro, NC

  Aug 1978 - Aug 1985

  Medical Finishing Sales Manager, Precision Fabrics Group, Industrial Division

  • 1984-85-Accountable for growing general cGMP based Medical Nonwoven Fabric Finishing business 35% in 15 months• 1983-Founding member of first Quality Performance Improvement initiative in Burlington Industries, where we assisted 3 divisions to make 3-7% improvement in bottom line profits in first 12 months.• 1981-On-site Division QA Manager at largest finishing plant in Blended Fabrics Division and interim Division Quality Manager where delivered quality performance to customers improved 7% points.• 1980-81-Promoted to Superintendent of Preparation support departments during introduction of new Rudi Air-jet weaving machines in plant modernization project• 1978-Initial manufacturing opportunities to be a Supervisor in fabric weaving and quality performance department manager. Show less

• 

  Freudenberg Nonwovens

  Aug 1985 - Jul 2002

  Director Continuous Improvement | Manufacturing Productivity Business Process Reengineering

  ➢ Used decentralized approach to create and deliver 12-15% productivity improvement by factory➢ Developed lean methodologies and tools to achieve > $2 MM cost savings in 80% of factories• 17 years in Automotive related industry with ISO-9001, ISO 14001, OSHAS 18001, TS-16949 related deployment experiences in all five North American facilities.• Led the facilitation for the development and execution of the functional areas continuous improvement objectives in support of the business unit’s operational goals for Freudenberg Nonwovens. • Helped develop and sustain a continuous improvement culture in which employees were empowered to improve technical and manufacturing processes. • Led a small corporate staff that was eventually decentralized to divisional / facility responsibilities to create and transform the culture and methodologies to sustain continuous improvement in five diverse North American based factories.• Provided assistance as a resource to the functional areas focusing on identifying projects by value stream / critical metric events that were high value opportunities for improvement. • Collaborated with functional departments, finance team and other members of Freudenberg Nonwovens in assessing, tracking and reporting the progress and financial benefit of Lean Six Sigma projects and Kaizen events. Show less

• 

  Adidas

  Jan 2003 - May 2006

  ➢ Created and delivered lean based training and support structure in the Americas Region• Created a successful liaison with Tier-1 apparel and footwear manufacturing contractors for both international and local sourcing throughout the adidas Americas sourcing theatre. • Utilized Lean and Six Sigma tools to analyze data sets and uncover areas for improvement. • Identified appropriate metrics to measure current state and measure process improvements for adidas and each supplier factory. • Designed and implemented continuous improvement projects and plans and set action timelines. • Drove projects forward and led cross-functional project teams to achieve long and short-term business growth objectives. • Provided regular updates to adidas and factory stakeholders in person; ensuring alignment and managed intra-dependencies across multiple continuous improvement projects. Show less

  • Continuous Improvement Manager | Cost Reduction Solutions

    May 2003 - May 2006

  • Sr. Continuous Improvement Regional Director

    Jan 2003 - Jan 2006
• 

  Thai Silp

  May 2006 - May 2007

  Director Productivity Continuous Improvement | Business Performance Excellence

  ➢ Reduced staff turnover by 75% through a teamwork based approach with performance achievement reward system➢ Achieved 12% improvement in productivity and a 5% point improvement in profitability within one-year contract period➢ Manufacturing lead-time reduced from 60 days to 45 days and on track for 35 days with a 15-day fast react system in place • Trained and managed a small 25 member staff of Continuous Improvement personnel and R&D staff to transform simple IE staff into a highly effective productivity and performance improvement staff, resulting in significant profitability improvements. • Responsible for providing effective communications with business leaders throughout Sterling while promoting continuous improvement opportunities and change initiatives. • Successfully promoted a healthy continuous performance improvement culture within Thai Silp Co. Led and administered multiple Kaizen and change acceleration events for various administration and production departments. • Responsible for creating specific short term and visionary, long term improvement plans and implementation training for selected business departments. • Redesigned change initiatives, provided leadership, and encouraged proper risk taking and willingness to make changes at all levels. • Developed future Continuous Performance Improvement Leaders and a succession plan for Thai Silp Co by the end of the one-year on-site work contract. Show less

• 

  Productivity Inc. - Asia

  Jun 2007 - Jan 2008

  Regional Director | Global Operational Excellence Continuous Improvement

  ➢ Achieved profitability within six-months of taking position➢ Provided counsel to department leaders for the development of training programs that supported the company strategy• Successfully implemented private consulting partnerships to support Asian Corporate Social Responsibilities and Productivity Performance Improvement needs. • Determined future avenues for administering learning and development programs such as eLearning and other computer-based systems. • Facilitated change management control methodologies and worked with management teams to assess training and development needs and ensure the implementation of changes and resulting performance enhancements. • Enhanced individual and team performances by creating a climate of continuous learning in support of the organization’s strategic initiatives. Show less

• 

  Asia Management Consultants

  Sept 2008 - Dec 2008

  Consultant | Operational Excellence Business Management

  Responsible for analysis, training, coaching and consulting activities to improve productivity and effectiveness of manufacturing and service companies throughout Asia. Worked with local consultants in countries to ensure best communications and minimize costs of services. Staffed in China, Thailand, & Vietnam.

• 

  Adidas Sourcing Ltd.

  Oct 2009 - Dec 2011

  Head Continuous Improvement | Global Supply Chain Performance Excellence

  ➢ Created and delivered lean based training and support structure in both Vietnam & Cambodia.Successfully managed and led a small consulting staff in Vietnam and Cambodia to drive continuous performance improvement methodologies in the adidas tier-1 supply chain for apparel, footwear and accessory & gear divisions (approximately 35+ independent factories) and 65-70 independent Tier-2 supply chain factories. Managed the planning, facilitation and completion of manufacturing systems projects and Kaizen (Rapid Process Improvement) events/activities to support the cost reduction objectives of local adidas Sourcing leadership. • Accountable for driving projects that delivered significant annual cost savings directly to the Tier-1/2 factories. Responsibilities encompassed capital projects, major manufacturing projects, kaizen activity and quick hit improvement activities. • Collaborated with the Footwear, Apparel, and Accessories & Gear Country managers for Vietnam and Cambodian factories and their operations staff to identify improvement projects and cost reduction opportunities. • Coordinated DMAIC based training for supply chain maintenance, manufacturing, engineering and project managers within the factories to ensure their internal program goals and objectives were achieved. • Worked closely with adidas’ quality department, materials sourcing supply chain to support overall performance improvements through quality, inventory & materials cost reduction goals and improvements. Show less

• 

  Coats

  Jan 2012 - Apr 2014

  Director Global Industrial Engineering, Continuous Improvement | Operational Excellence

  ➢ Successfully enabled $5MM annualized bottom line performance cost reduction savings (2012) to grow to $12MM (2013) and $15MM (2014) annually.➢ Spearhead the integration and formalization of continuous operational performance improvement and industrial engineering activities to bring about Best Practices in dominant global sewing thread supplier to deliver significant performance improvements resulting in continuous cost reductions and profitability improvements• Provide quality support to the production support teams. Assist in developing, implementing and sustaining quality systems and practices. Manage cross-functional teams to improve products, processes, services, and to reduce costs for Coats PLC.• Facilitate cross-functional teams in utilizing systematic process improvement techniques and support of lean six sigma implementation. Provide statistical process controls and design of experiments expertise to assist in implementing control plans, charts, and capability studies.• Develop and implement continuous improvement programs for internal processes and throughout Coats’ supply chain. Provide feedback and employ corrective actions to enhance supplier partnerships and exceed quality requirements.• Monitor and regularly report on product quality and reliability; provide timely feedback to the appropriate functions for corrective preventive actions. Assist in new and modified product designs at the NPI stages to ensure quality and reliability of Coats’ products.• Effectively redesigned and utilized an existing corporate project management system to follow the DMAIC methodology utilized on Lean Six Sigma projects and Kaizen events that enabled monthly project progress reporting and upon completion financial impact realization.* Mentor of Lean Principles in production operations, manufacturing operations, administrative settings including inventory control, warehouse operations, job shop operations, & safety program improvements. Show less

• 

  International Leader & Mentor in Global Operational Excellence

  Jan 2014 - now

  Founder | Global Operational LEAN Based Performance & Effiency Excellence.

  • Creating corporate strategy & global multi-site training in industrial and manufacturing organizations with outreaching interpersonal skills especially in training situations.• Researching and helping Business Leaders Drive Performance Improvement• Hands-on training in Problem Solving with LSS Techniques to improve operational efficiency & effectiveness, with TPS (Toyota Production System) Kaizen Leadership training & implementation, A3 Problem Solving Strategies, integration of Maintenance into production operations with TPM.• Participating in Compelling New Business Discussions and Strategies• Sharing Strategic Connections by Business & International Professionals• Directed global transformational change to an evolving organization• Techniques for aggressive waste elimination through a Kaizen approach to continuous improvement (CI) including facility Warehouse Management Systems and Process Design integration.• Continuous Process Improvement and Business Process Management techniques & discussions• The use of Customer Engagement to grow your company* Focused on Kaizen or Rapid Improvement Activities as a means to engage the local workforce and Continuous Improvement professionals in this global improvement effort. Show less

• 

  LegalShield

  Jan 2015 - now

  Manager

  I help individuals and their families create peace of mind through LegalShield & IDShield memberships, either directly or as employer sponsored. No one should should be without Identity Theft protection or without legal support. Call or reach out for help..!bf

• 

  Insight Home Inspections

  Aug 2016 - now

  Licensed NC Home Inspector # 3765

  Perform presale home inspections for sellers or buyers to protect the most expensive purchase anyone makes - their home. I treat client's homes like their were my own with focus on safety and protecting your investment. I also perform pre-drywall inspections for those clients building their own homes.Remember PROTECT yourself, your family and your biggest investment from the start, NOT after the purchase..!bf

• 

  American Red Cross

  Nov 2018 - now

  AMERICAN RED CROSS Volunteer