Bob Bailey
Senior Management Consultant
Mr. Bob Bailey is a Lean expert having actively applied the technologies of continual improvement and waste reduction methods leading to measurable business results for the past 30 years. Bob's areas of concentration are Lean Manufacturing, Six Sigma disciplines, and the acceleration of core business processes. He has experience in multiple industry sectors including the high-tech, manufacturing (light & heavy), construction, and transportation industries.
Currently, Bob is a Senior Management Consultant with MainStream Global Solutions (MainStream GS). In his role at MainStream, Bob's focus is on the application of Lean principles to aircraft MROs. Bob's primary responsibility is to lead cross-functional teams in the re-design and sequencing of work steps to reduce repair cycle times.
Recently, Bob led an initiative to reduce production flow days for an attack aircraft for the U.S. Air Force. This initiative led to a reduction of 58% in production flow days and overtime hours being reduced by 80%. In another recent engagement, Bob led an effort which resulted in reducing the repair cycle time for a major sub-assembly by 46% and overtime by 70%.
Prior to joining MainStream in 2003, Bob was a Lean Consultant for Quality & Productivity Solutions, Inc. In this role, Bob worked with over 50 clients, across the United States, Canada, South American and Europe, including Caterpillar, York International, Flowserve, Hewlett-Packard, Schlumberger, Hitachi, Motor Coach Industries, Yanbal, General Cable, Doskocil, and Keystone.
Bob worked for Hewlett-Packard Company (HP) for 15 years during which time he held a wide range of challenging positions in R&D, manufacturing, and quality. While at HP Bob developed an environmental stress test known as STRIFE which contributed to a ten times improvement in product reliability and a dramatic reduction in warranty costs. In addition, Bob was key in guiding the manufacturing team to reduce cycle time between product release and first customer shipment from six weeks to less than five days, while simultaneously implementing cost reductions and taking actions which resulting in improving overall customer satisfaction. During his tenure with HP, Bob studied under Dr. W. Edwards Deming, Dr. Eliyahu M. Goldratt, and Mr. Dorian Shainin.
Bob is a published author, with numerous works having appeared in publications including IEEE Transactions on Nuclear Science, Government Microcircuits Conference Digest of Papers, Institute of Environmental Sciences Proceedings, and Manufacturer Magazine. His works cover topics in application of Lean techniques in both manufacturing and non-manufacturing environments, stress testing as a product development tool, and high frequency measurements.
Prior to joining HP, Bob served as an officer in the United States Air Force (USAF). While stationed at the USAF Weapons Laboratory, he developed the mathematics for a production line technique used at the wafer level to identify radiation tolerant semiconductor devices. During his time in the USAF Bob also worked with the National Bureau of Standards to develop a method for characterization of a high frequency probe used to measure test devices on integrated circuit wafers.
Bob earned his BSEE from the University of Detroit, and MSEE from Colorado State University. In addition, he has completed the academic requirements for a Ph.D. at Oklahoma State University.