Bob Forshay – Business Leadership

CPIM, CIRM, CSCP, CLTD, CSCA, CSCM, CLM, CSCTA

Professional Resume

Summary of Mr. Forshay has over 30 years of experience delivering effective supply chain and
Qualifications manufacturing solutions applying Lean & Six Sigma best practices for manufacturing and
service organizations. Mr. Forshay has extensive experience as a business leader,
galvanizing teams to higher performance as a visionary, mentor, coach, innovator,
project leader, change agent and instructor/consultant directing change for high
performing organizations. His leadership efforts have led to measurable results both in
top line revenue and gross margin by focusing on process effectiveness and efficiency,
value oriented customer satisfaction and superior market performance. His ability to
leverage his expertise and collaboration skills with a bias for results has yielded millions
of dollars of benefits to the bottom line across multiple industries. His primary focus is
leveraging talent and skills of the team members for strategic deployment to achieve
exceptional results. Bob’s management approach to organizational performance
improvement is on proven methodologies emphasizing Lean & Six Sigma providing
profitable results for dozens of companies plus over 4000 hours of classroom education
delivered to university, APICS and ISCEA certification programs to thousands of
professionals since 1989.

• Strategy Development, Deployment, Alignment & Execution

Areas of • Leadership Development& Training, Developing High Performance Teams
Expertise • Supply Chain Assessment, Lean Supply Chain as a Core Competency
• Demand Management & Forecasting to improve Service and Cost performance
• Sales & Operations Planning – Excellence in Manufacturing and Fulfillment
• Process Performance Improvement as a Culture for Sustainability
• Customer Service Oriented with maximized profits in Inventory Management
• Change Facilitator, Program & Project Management & Communication
• Supplier Relationship/Quality Management and Balanced Scorecard
• Strategic Sourcing supporting company Execution Goals & Customer Service
• Lean Six Sigma consulting, training & coaching (Certified Lean Master)
• Visual Management, 5S, Kanban, Flow for Performance, Lean Transformation
• Manufacturing Operational Excellence & Shop Floor Flexibility
• Performance Management for Accountability and Transparency
• Program & Project Leadership – Process Improvement & Product Introduction
• MetaOps Training - Certified Supply Chain Transformation Architect (CSCTA)
• The Fresh Connection – Web Based Simulation Training

• Storage Area Network devices, hardware and software

Industries • Automotive Tier One
Served • Oil field service equipment
• Construction, site prep and heavy highway
• Mining and Milling Operations
• Reclamation heavy metals processes
• Food processing, Co-Packer, Bakery, Dairy, Meat
• Beer, wine production and bottling

6525 Gunpark Dr, Suite 370 -104, Boulder CO 80301

P 720-524-7258 | F 888-898-6817
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Bob Forshay – Business Leadership
CPIM, CIRM, CSCP, CLTD, CSCA, CSCM, CLM, CSCTA

• Air filtration equipment

• Healthcare – patient services
• Clothing manufacture
• Photographic films
• Optics & Laser Assembly
• Automotive OEM & aftermarket products
• Steel & metals Fabrication – Measurement Devices, Industrial, Medical
• Electronic printed circuit cards and electromechanical assembly & test
• Medical x-Ray device manufacturer
• Plastics Injection Molding
• Paper and Pulp Manufacturing
• Robotic welding equipment manufacturer
• Wind energy and speed control equipment
• Helicopter and airframe maintenance
• Aircraft communication equipment manufacturer

Leading and working with Teams each environment;

Professional
Experience • Consulting and Leadership coaching for supply chain and business leaders since
2005 including Fortune 500 firms.

• Sr. OEM Program manager responsible for fulfillment of top line revenue plan for
$450M with P&L alignment of 3 tier of supply chain partners as well as smaller
firms from $10M.

• Providing the framework for delivering transformation creating ROI through

leadership development & training, strategy development & alignment,
organizational infrastructure design, process management, change management
& strategic Lean 6 Sigma business improvement to Fortune 500 companies

• Guided implementation of lead time and inventory reductions in multiple firms while
improving On-Time-Delivery and Customer service increasing profits

• Developed and implemented scheduling & capacity management for heavy highway
construction equipment to maximize utilization, reducing equipment moves by 20%.
Reduced job costs allowing more competitive bidding.

• Increasing ROA consistently year over year by improved scheduling for construction
& materials increasing equipment availability and site readiness for oil & gas and
commercial construction sites. Standardized scheduling processes for equipment
labor and transportation.

• Conducted assessments and led Global SCM improvement initiatives.

EMC/McDATA enjoyed $10m-$15M revenue increase quarterly. Fisher Imaging
reduced lead time and inventory by more than 50%. Micro Motion attained On-time-
delivery consistently over 98% while reducing lead time 12 wks to 4 hrs.

• Advised on design and configuration of Oracle and Agile systems integrating

supporting roles in Sales & Operations Planning, Financial Analysis of Demand,
Vendor Managed Inventory, Master Scheduling, and Capacity Planning.

• Advised quick turn injection molding firm teams in reengineering their Quote-to-
Delivery process to include customer collaboration leveraging internal skills serving a
niche market with quick turn tooling.

6525 Gunpark Dr, Suite 370 -104, Boulder CO 80301

P 720-524-7258 | F 888-898-6817
2
Bob Forshay – Business Leadership
CPIM, CIRM, CSCP, CLTD, CSCA, CSCM, CLM, CSCTA

• Trained multiple teams on Value Stream Mapping and A3 Problem Solving tools for
lean initiatives reducing lead time up to 25% or more in some cases.

• Trained over 400 personnel implementing Lean initiatives for medical xRay firm
supporting 2 core product lines reducing E&O Inventory by $8 million. Implemented
lean cellular manufacturing and Kanban supporting visual flow capability. Designed
and implemented a lean engineering change control process to reduce ECO
implementation lead time from 7 months to 6 weeks.

• Sample of organizations served: McDATA, EMC, Dell, IBM, HP, Lexmark, Mount
Sopris, Tesoro Oil & Gas, Whiting Oil & Gas, Encana, Nobel Oil & Gas,
Schlumberger, Otterbox, Neon, Aurora Organic Dairy, Niner Bikes, Fresca Foods,
Vestas Americas, SpectraLogic, BI, Medtronics/Covidien, Heli-One, Fischer Imaging,
Micro Motion, Rosemount, Emerson Process, Kodak, Teledyne-Waterpik, Wolf
Robotics, Advanced Energy, Woodward, PTA Plastics, Leed Fab, Norgren
Engineering, NATEX, Golden Construction & Concrete, Plains Aggregate, Flatirons
Construction & Hendricks Mining & Milling, Engro Foods Ltd., Civeo, Amgen, Natural
Dog, Rubadue Wire, Pearl Izumi, Colorado Memory Systems.

• Certified Lean Master - Supporting the Certified Lean Master program for the
International Supply Chain Education Alliance under Transformance Advisors
label. Scope including manufacturing, distribution, retail, various service orgs,
health care. Focusing on alignment, process excellence, change management &
strategic Lean 6 Sigma business improvement services to Fortune 500
companies.

• Master Instructor, APICS and ISCEA certification programs with over 4000 hours.

• Course writer and instructor, Front Range Community College, Community

College of Denver, Community College of Aurora, Greenforest, Leoron & others.

• Trainer (North America) for The Fresh Connection – web based simulation
platform demonstrating various approaches to supply chain challenges supporting
executive and management leadership decision making skills.

• Adjunct faculty instructor for Front Range Community College, for 5 years. Wrote
program and course for Advanced Manufacturing Management Systems.

• COO (currently) & Past President (1994-95). Member of Board of APICS Northern
Colorado, Society for Operations & Supply Chain Management from 1988.

• Hands on experience in manufacturing steel fab precision products, high and low
volume high-tech electronics, network storage products and software, medical x-
ray equipment, food process, bakery, dairy, oil field equipment, construction
heavy highway and structures.

• Owner- CEO, Mastermind Group, LLC, Training and consulting firm for operations
and supply chain clients worldwide. Author, speaker and business writer.

A Sample of • Implemented a Sales & Operations Planning Process to reduce inventory and
increase service levels by 2X effectively increasing revenue over time.
the Success
Stories • Helped MTO Mfg client to win over $1M within new business within 30 days by
reducing LT on critical purchased parts from 24 weeks to 8 weeks.

6525 Gunpark Dr, Suite 370 -104, Boulder CO 80301

P 720-524-7258 | F 888-898-6817
3
Bob Forshay – Business Leadership
CPIM, CIRM, CSCP, CLTD, CSCA, CSCM, CLM, CSCTA

• Client reduced LT of low volume-high mix parts by establishing a Master

Schedule, a Kanban stocking Supermarket and strategic purchasing to reduce LT
from 20+ to 2 -3 weeks.

• Reduced fulfillment lead time to deliver configured product from 2 weeks to 2

hours achieving up to $45M per quarter with 20% gain over 2 years.

• Reduced lead time and inventory by more than 50% implementing a lean process.

• Achieved supplier ranking consistently in top 4 suppliers for Dell supporting a

global network with a 98% or better service level

• Improved on-time delivery performance from 54% to 98%+ with Inventory turns
improved from 1.2 to 36/year with reduced lead times by 75% while adding 2
product lines.

• Custom Engineered products lead time decreased from 22+ weeks to 3.5 weeks
for 98 % of orders with revenue growth from 3% to 24%.

• Realized capacity gain of 500%+ ROI in 90 days with spend of < $4000.

• Client reduced warehouse handling by over 70% with new workflow and layout
saving more than 20% warehouse labor cost.

• Reimplement stalled ERP in client running 50% MTS 7 50% MTO to improve
delivery at reduced cost, with shorter lead time.

• CSCTA - Certified Supply Chain Transformation Architect – Meta-Ops

Accreditation • CLTD – Certified Logistics, Transportation, Distribution - APICS
& • CSCP – Certified Supply Chain Professional – Program Instructor – APICS
Certifications • CIRM – Certified Integrated Resource Manager – APICS
• CPIM – Certified Production &Inventory Manager – Program Instructor – APICS
• TTT – Train the Trainer – Instructor - APICS
• CLM – Certified Lean Master – Program Instructor – ISCEA
• CSCM – Certified Supply Chain Manager – Program Instructor - ISCEA
• CSCA – Certified Supply Chain Analyst – Program Instructor – ISCEA
• Master Instructor APICS programs

• Instructor evaluation score = 5.58 out of 6 with 6 = Excellent, with 80%-85% first
time pass rate compared to the 55%-72% nationally and over 4000 hours. TTT,
Train the Trainer certified 1993 and renewed in 2000 (qualified instructor) and
LDI, Learning Dynamics for Instructors certified in 2001 maintained annually.

• Adjunct Faculty, Front Range Community College – 1993 to 1998.

• Public speaker for APICS, SAPICS, 6-Pack APICS Terra Grande, CSCMP,
Denver Transportation Club, PMI, SHRM, SME, ISM-NAPM and ASQ and others
in USA and abroad.

See additional details on Bob at https://www.linkedin.com/in/bobforshay

Misc. Experience over the years;
• P&L management, project & budget planning, business plan writing, SWOT
analysis, strategic planning
• Real estate investor, property manager residential
• Engineering product data/change control, documentation, architectural drawing

6525 Gunpark Dr, Suite 370 -104, Boulder CO 80301

P 720-524-7258 | F 888-898-6817
4