Andy Andrews
Senior Management Consultant

Andy Andrews is a Senior Management Consultant and supply chain expert for TBM Consulting Group with over 20 years of management and operations experience across the value chain. Andy has a proven track record for helping clients transform their supply chains, logistics, transportation, distribution and warehousing using lean principles and methodologies. He has extensive expertise in logistics and transportation operations design and implementation.

Before joining TBM, Andy served as a Manager of Operations for the Transportation Management Services Group at Penske Logistics. He has also previously held positions at Rowe Furniture as a Director of Logistics, RBX Corporation as a Director of Transportation, Roadway Express as an Operations Manager and MA Hanna Corp., where he introduced lean techniques and led the company through their lean transformation.

Andy has consulted with numerous clients in food manufacturing, industrial products, medical devices, aerospace and building products to reduce supply chain costs, consolidate footprints, improve on-time delivery, develop lean distribution centers, reduce inventory and increase productivity.

Some examples include helping a ConMed Corporation to design and implement a new model for product distribution that will reduce annual logistics costs and increase its error-free fill rate. He helped Franklin Electric with detailed demand segmentation and SKU rationalization to drive significant reductions in finished goods inventory. He leveraged his in-depth supplier management experience to help Bimbo Bakeries renegotiate transportation contracts worth hundreds of thousands of dollars in targeted cost savings.

Andy earned a Bachelor of Science degree from Clarion University of Pennsylvania and International Trade Certification from Radford University.

Doug Bonner
Senior Management Consultant

A LeanSigma Master Black Belt and holder of two advanced degrees, Doug Bonner is a recognized expert in quality initiatives and in the integration of lean and Six Sigma. Doug has unique skills in key business areas such as flow improvement, quality improvement, material supply and replenishment, and value chain mapping.

Doug has over 15 years experience as a trained LeanSigma Expert. He received his black belt training at General Electric’s Aircraft Engine Manufacturing and Assembly division where he worked for 11 years. During that time, he advanced to become a unit manager and was selected to help key-client, Boeing Aircraft, implement and integrate Six Sigma with their continuous improvement program.

While at TBM, Doug has been an advisor to over 55 different companies in a variety of industries. Doug has broad experience leading lean transformations with continuous process manufacturing companies such as Sappi Fine Papers, Michelin Tire NA, Kodak, Nichols Aluminum, Doncasters, Rieter Automotive, Kaiser Aluminum, Indalex, Special Metals, Howmet, Serono Pharmaceutical, Roche Pharmaceutical, McCain Foods, Special Metals, Appleton Paper, Bunge, Solae, and Phifer Wire. Doug has AAMI QSR Certification.

Doug has a Bachelor of Science degree in Industrial Engineering from Georgia Tech, a Masters of Science degree in Mechanical Engineering from Colorado State University and an MBA from the University of North Carolina at Chapel Hill. Doug is also a certified Professional Engineer in Environmental Engineering.

Ku Ho (Jonathan) Chong
Director, Business Development

A former engineering and commodities manager with a solid background in lean and Six Sigma, KuHon (Jonathan) Chong came to TBM in 2004 after leading continuous improvement and product development efforts for 15 years for select Fortune 500 companies, such as IBM, Motorola, and Applied Materials.

At TBM, KuHo has been one of the key leaders in the successful LeanSigma transformations of large multinational food and beverage companies, such as McCain Foods and Bunge, and of high-technology companies such as Freescale Semiconductors.

KuHo also has been instrumental in utilizing LeanSigma tools to promote operational excellence and cultural transformation in large medical industry clients, such as Hill-Rom and Genzyme Corporation. His strengths are in using statistical tools to improve yield and process capabilities and in new product development.

KuHo earned a Master’s degree in Aerospace Engineering and a Bachelor’s in Mechanical Engineering from Cornell University. He speaks fluent English, Korean, and Spanish.

Carl Deeley
Senior Management Consultant

Carl Deeley is a specialist in lean value chain design and implementation. Originally from the UK, he has worked across Europe, the US and Asia to help companies develop sustainable business models and profitable growth.

Carl joined TBM in 1998 after undergoing extensive training in lean leadership at the Toyota training center in Nishin, Japan. At Toyota, he successfully managed plant start-ups and developed an expertise in value chain design and supplier development to help a variety of businesses implement lean production systems. His experience in production planning also includes new product introductions, logistics and supplier partnerships.

Carl began his career with GKN industrial and quality engineering and was later group quality manager with Newman Tonks and engineering project manager for DAF Trucks. He holds a degree in mechanical and production engineering and has been a trusted advisor to companies such as TRW, Mars, McCain Foods, Sealy, JCB, Alstom, Tracker Marine Group and Hubbell Inc.

Nero Haralalka
Senior Management Consultant

A LeanSigma master black belt with a background in Product Development and statistical problem solving, Nero Haralalka came to TBM with 15 years experience in manufacturing management.

Prior to joining TBM in 2000, Nero was a manager in charge of product / process development and quality at Freudenberg NOK, where he was also responsible for coordinating projects globally. Nero was senior manager of product and process development in the engineering and technical departments of Aeroquip Elastomers. He was also a design and test engineer for New York Air Brake and Thrall Car Manufacturing.

Nero has become particularly sought after for his ability to lead and motivate teams, from the shop floor to corporate offices in all aspects of LeanSigma including Manufacturing and Business Process. He has lead the transformations with many world class clients and worked closely with companies such as Genzyme Pharmaceuticals, Freescale Semiconductor, Pactiv, Carlisle Construction Materials, Energizer, McCain, Kaiser Aluminum, Hubbell, and St. Jude Medical. In 2009 he consulted for 6 months at Pactiv as Director of CI and supported their Lean Initiatives from Policy Deployment implementation to Cost Reduction projects, resulting in breakthrough performance.

Nero has a Masters in Mechanical Engineering from Illinois Institute of Technology, Chicago and a Bachelor’s in Mechanical Engineering from the Birla Institute of Technology in Ranchi, India. He also has an AAMI Certification in the FDA CFR (Code of Federal Regulations) Quality Systems Requirements and Industry Practice.

Ken Koenemann
Vice President, Business Development and Marketing

A lean leader with more than 16 years of experience with lean and Six Sigma implementation across the value chain on both the shop floor and in business processes, Ken Koenemann brings to TBM expertise in teaching and coaching lean and value-chain concepts and using those concepts in sourcing, manufacturing, warehousing, distribution, and planning and scheduling processes.

Before joining TBM, Ken was director–delta at American Greetings in Cleveland, OH, where he served as a leader of the internal strategy and consulting organization focused on delivering large transformational projects to meet strategic objectives. While there, he led the redesign of the seasonal card business, and initiated a business-process redesign effort to enable new go-to-market strategies and reduce costs. Earlier in his career, Ken was Managing Director Consumer & Industrial Market Supply Chain practice where he worked as a consultant to large and mid-sized consumer and industrial companies implementing lean and Six Sigma across supply-chain operations.

As Managing Director of TBM’s Lean Value Chain Practice, he has focused exclusively on delivering Lean Value Chain training and implementation with companies such as Assa Abbloy, ConMed, Energizer, McCain, Pactiv, Sealy and WIKA Instruments.

Ken’s lean experience began with Toyota Gosei, where he was responsible for deploying TPS in the manufacturing operations in the US as well as in the supply base. He was trained by two original members of Taiichi Ohno’s Autonomous Study Group and spent six months in Japan learning and implementing TPS. He has a Bachelor of Arts degree in management from the University of Missouri–St. Louis.

Tom Morin
Director, Business Development

Tom Morin has over 20 years of global experience leading business-wide LeanSigma transformations and driving cultural change in manufacturing and service organizations. He is particularly recognized for his broad experience implementing strategy deployment, leading business process improvement, driving lean implementations and training continuous improvement professionals in technical areas including: set-up reduction, machining and fabrication.

Tom has been a trusted advisor for clients such as Reviva, Hillenbrand, EA Sween, Allied Signal Carlisle, State of Iowa and Hayward Pool Products. He is often called upon to teach courses for the TBM LeanSigma Institute. He now leads business development efforts by working with prospective clients and helping them define the scope of training, technology and consulting services they require for achieving effective business results.

Before joining TBM, Tom was an operations and continuous improvement manager at Otis Elevator for nearly 10 years. He was trained in lean by Shingijutsu consultants. He also taught Flexible Manufacturing for UTC Corporation in divisions throughout the world.

Beth Morrison
Senior Management Consultant

A LeanSigma master black belt with 24 years experience in aerospace and nuclear-submarine manufacturing, Beth Morrison comes to TBM with an extensive background in training and mentoring.

Beth has been a leader in nearly every aspect of the value chain, from business analysis to sales, from research and development to fabrication. She has applied the tools of continuous improvement in each of these areas, leading initiatives in manufacturing and business processes, and has mentored Six Sigma green belts and black belts through hundreds of projects.

At GE Engine Services, Beth was in engine service sales and spent two years as a regional airline customer service manager. At Boeing Commercial Airplane Group, she specialized in research and development. Before that, Beth was a manufacturing engineer and worked as a shipyard supervisor in the pipefitting trades on nuclear submarines. Beth has AAMI QSR Certification.

Beth has a Master’s degree in Management from Webster University and a BS in Civil Engineering from Worcester Polytechnic Institute.

Joe Panebianco
Director, Training Solutions

A former operations manager with broad manufacturing and business experience, Joe Panebianco joined TBM in 2003 and currently serves as Director and Team Leader of the TBM LeanSigma Institute.

As operations manager at Paramount Die Company, Joe implemented lean principles throughout the organization, reducing lead time by 90 percent and eliminating all late orders for the first time in the company’s history. During his tenure at Bayside Controls, Inc., Joe held leadership positions and was part of the management team that grew the company 50 percent annually, for six consecutive years, transforming Bayside from a small machine shop to a leading manufacturer of precision gear systems.

Joe is the author or numerous articles on the subjects of continuous improvement, training, culture change, and e-learning. He is a regular contributor to TBM’s Managing Times and has also been published in Training and Manufacturing.net. Joe has also presented at conferences and webinars on the topics of Managing for Daily Improvement, Ten Best Practices of a Continuous Improvement Office, and Energy Kaizen.

At TBM, Joe is sought after for his team-building and leadership skills, as well as his ability to help clients visualize and develop a transformation plan. He is uniquely skilled in effectively interfacing with all levels of an organization to facilitate change. Since joining TBM, Joe has become a trusted advisor to companies such as Owens Corning, Gokaldas – India, American Achievement Corproation, Energizer, Assa Abloy, Hubbell, Pratt & Whitney, EnPro Industries, and Special Metals Corporation.

Joe has a Bachelor of Science degree in Electrical Engineering from Loyola College in Maryland.

David Pate
Global Client Manager

A skilled business leader with experience in both process and discrete manufacturing, David Pate is recognized for his ability to deliver results and for his expertise driving lean transformations, facilitating culture change and developing lean leaders.

David’s experience with lean leadership began in the 1990’s when his company worked with Toyota to implement the Toyota Production System. His career includes progressive levels of responsibility in operations at Collins & Aikman automotive where he served in multiple positions including director of lean manufacturing, director of planning and plant manager. In his role as director of lean manufacturing, David led lean transformations for four large factories and implemented a program for lean supplier development. As plant manager, he utilized lean to drive and sustain significant reductions in defects and increased productivity.

At TBM, David spends most of his time working with senior executives at client companies helping them to begin their lean transformations and successfully execute their strategic objectives through the use of strategy deployment (hoshin kanri). He works closely with clients to ensure that their continuous improvement initiatives are clearly aligned to strategic initiatives and key performance measures. Recently, David has engaged heavily with private equity firms to perform due diligence in advance of potential acquisitions. Once those portfolio companies are acquired, Keith often works with portfolio company management to implement sustainable improvements and with the PE firm to maximize their investment.

He has worked in diverse industries with many TBM clients including McCain Foods, Bunge, Nike, Carlisle, Mettler-Toledo, Simpson and IMS Health to drive results, develop lean leadership, and implement sustainable culture change.
David also takes an active role in his community through active leadership and youth counseling in Mebane United Methodist Church, local athletic programs and in supporting his entrepreneurial spouse.

David has a Bachelor of Science in Business Administration from Appalachian State University and has earned a Certification in Production and Inventory Management.

Jim Privette
Senior Management Consultant
Jim Privette brings over 30 years of manufacturing process leadership and 17 years experience in Lean and Six Sigma to TBM. An expert at implementing 5S, coaching, process and value stream mapping and other Lean techniques, Jim brings this valued expertise to enhance manufacturing and supply chain environments.

Prior to joining TBM, Jim spent more than 25 years working with Honeywell International (AlledSignal) in several divisions, including Chemicals, Fibers, Florglas (PTFE), Plastics, Amorphous Metals, Engineered Materials Sector and Corporate Six Sigma Group. During this time, he was responsible for being a change agent who introduced the continuous improvement mindset using Six Sigma and Lean to the corporation. In this role, Jim was a master facilitator, working with business unit senior leadership teams, under the direction of CEO Larry Bossidy’s Leadership team, and implementing such programs as TQ (Total Quality) process, TQ through Speed (Lean) process, TQMP (maturity path) process and the Six Sigma Plus process. During his tenure, Jim was promoted through a series of leadership roles that reflected his growing knowledge, enhanced expertise and increased responsibilities. His work and accomplishments earned him special recognition awards for safety, quality and productivity improvements.

Jim also served as a Corporate Lean Champion at Sonoco Products Company for five years implementing the Lean Production System.

Jim is a Certified Master Blackbelt and earned a BA in Finance and a MBA from the University of South Carolina. He enjoys fishing and is a sports fan.

Gary Rascoe
Senior Trainer and Design Specialist
A LeanSigma black belt with extensive experience in both Operations and business processes, Gary Rascoe came to TBM in 1995.

Gary is especially sought after for his expertise in integrating business processes with lean operations and has led successful kaizen events and company-wide lean implementations for more than a decade. Gary joined the TBM Institute team in 2007 and has focused on helping organizations sustain results.

As a lean internal consultant for United Technologies Corporation, Gary led kaizen teams to create plant-wide lean transformations world-wide. Prior to that role, he was a manager of Organizational Effectiveness for UTC in Canada and attended the one-year European-based Otis University training program in lean manufacturing and purchasing.

At TBM, he has been a trusted advisor for companies such as Deli Express, Hayward Pool Products and Reviva.

Gary has an MBA and an undergraduate degree in Business Administration with a Human Relations emphasis from the University of Connecticut.