About Byron

I have over 15 years experience as a successful Lean implementer. I understand what it takes to transform businesses large and small in both manufacturing and office/service environments. As a Lean visionary and creative thinker, I have been able to develop a successful approach for deploying Lean in both office/service and manufacturing systems.

I have used this approach to drive large scale improvements. Some specific examples include:

• Using Strategic Value Stream Mapping to develop and improve value proposition for end customers of a three-facility business group within a division of a Fortune 200 Company. The End Result – An 18.7% sales volume increase across all sites and an overall profit improvement greater than 50%.
• Increasing a manufacturing plant’s On-Time Delivery of products from the low 70% range to the mid-90% through the implementation of pull systems, standardized work, setup reduction, and error proofing techniques.
• Decreased Customer Inspection Rejects Metric at a manufacturing plant, from over 60,000 defective parts per million (dppm) to less than 300 dppm through the deployment of Design/Process Failure Modes and Effects Analysis and 8D Problem solving teams.
• Deployed Lean office work flow techniques across multiple businesses to reduce order processing time for custom designed orders from twenty-one days to seven and reduced standard catalogue order processing from seven to three days.
• Served as Senior Project Manager on new production lines, integrating facility planning with Lean techniques such as continuous flow and error proofing. Project experience ranges across multiple industries: industrial equipment, food processing and automotive.
• Mentored multiple make-to-order job shop manufacturing companies in lean deployment with success. One example: Over an eight month period increased efficiencies and quality in order to allow a family-owned machine shop to grow from $40K in monthly sales to over $80K.
• Certified Six Sigma Black Belt

While many of the above improvements occurred throughout my career as an employee, in February of 2009, I formed Lean Frog in order to share my abilities and expertise throughout the southeast, primarily north Alabama, Georgia and Mississippi along with southern Tennessee.

I am your local expert. Contact me today!

What Do People Think about my Work?

“ This economy is tough for everyone. What is experienced by our patients and physician partners is also true for us. We each need be as efficient as possible, excellent in what we do, and always focused on delivering specific and measurable value unto others. To that end, I need all the help I can find making my medical practice the very best it can be! I am really impressed at how Byron at LEAN Frog has been able to help me. Byron takes LEAN principles he perfected improving other processes at Fortune 500 companies, and applied them to my real-world needs in a rural medical office setting. Yes, what he delivers really works! We have daily processes that can be analyzed, simplified, and improved. Byron stands above others we have consulted with in that he understands how to achieve organizational “human” buy-in and participation; thus making the new changes really work, lasting perpetually, not just the first month! Byron’s team at LEAN Frog excels in thoroughly making our processes better. Not just for the sake of achieving LEAN qualities, but for the sake of meeting our real needs and values. He has a knack for making sure every step of his program delivers VALUE that drives forward our medical practice goals. LEAN Frog, we thank you.”
– Gabriel Dreiling, Practice Manager, Valley Imaging Center, freestanding radiology office, Athens, AL

“We’d been trying to deploy Lean manufacturing techniques for years with only limited success. After completing a strategic value stream map of the company with Byron’s help, my team was able to pinpoint exact cost-saving opportunities. While these opportunities were being pursued, Byron was able to roll out a Lean management system composed of leadership standardized work, visual controls, and a daily accountability process. This Lean management system has allowed us to sustain improvements and taken Lean to the next level, truly transforming the company’s culture. While Byron continues to assist with Lean deployment in manufacturing, together we have begun to deploy similar Lean techniques to the company’s administrative functions in Human Resources, Purchasing, and Finance.”
– Lynn Ozier, President, Willo Products Inc., Decatur, AL

“Byron is master practitioner of Lean and possesses an astute knowledge of how businesses work. I highly recommend Byron for your Lean endeavors.”
- Mike Lothspeich, Plant Manager, Eaton Corporation, Decatur, AL

“Byron takes an effective, systematic approach to continuous improvement. He creates an engaged workforce that focuses on the agreed upon goals. He works well with all levels of the organization. I recommend that anyone wanting to develop a lean culture would contact Byron. He will help you develop a solid foundation for lean improvement.”
– Kevin Evenson, Lean Manager, Eaton Corporation

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