Company

Team Member Profile

Robert Klym

SENIOR PROCESS IMPROVEMENT SPECIALIST

Like many of the industry's finest Lean Facilitators, Robert was given thorough training an all aspects of Lean systems, processes, and tools while rising through the ranks as an employee at Toyota Motor Manufacturing in Georgetown, Kentucky. Robert performed successfully on the front-line in the paint shop, and then won promotions to Team Leader and Group Leader. Toyota's leadership training for those supervisory roles is a thorough and transformational as their Lean system training.

During his nine years at Georgetown, Robert was involved in three new model launches, which always require mastering complex new systems and technical processes. He was regularly engaged in training his team and developing standardized work. He led a number of process improvement events, one of which eliminated a JD Powers defect and led to savings of $1.25 million.

As the U.S. automotive industry began to adopt Lean, Robert became the Manager, Competitive Manufacturing Group for General Motors Corporation (GM) at Pontiac, Michigan. In this capacity, he served as a coach and mentor for the leadership teams of 21 Powertrain plants across North America, focused on helping those teams develop and execute strategic Lean Manufacturing implementation plans. He participated in the Lean Manufacturing Assessment Program, and evaluated the status of implementation and performance at Powertrain facilities in the United States, Canada, Mexico, and Australia. During his eight years at GM, Robert trained over 1,000 employees in Lean Simulations and Problem Solving.

Some of the key improvements that were developed at GM under Robert's leadership included:

  • 32% improvement in First Time Quality; 48% increase in hourly production at an engine plan in Australia
  • 27% reduction in finished goods inventory; 13% increase in daily production at an engine plant in Romulus, Michigan

In August, 2005, Robert formed the Barek Group, LLC, to provide his knowledge and skills, plus those of his team to a variety of organizations. His clients and examples of the associated improvements have included:

The Bay Area Rapid Transit System (BART)
  • 81% reduction in purchase order lead time
  • 31% reduction in required warehouse storage space

The United States Air Force
  • $2 million of savings by eliminating quality issues
  • 58% reduction in the time required to conduct standard aircraft inspections and repairs

Detroit Medical Center
  • $500K reduction in inventory in a single Pharmacy location
  • 31% increase in "On Time Starts" in the Operating Department

At OPS, Robert utilizes his extensive background in all aspects of Lean to assist with training and process improvement projects for clients in government, healthcare, and manufacturing.