Tony Roberts - Senior Advisor

As a Senior Advisor at TriVista, Tony works closely with clients on Lean and Operational Improvement Projects to execute shop floor improvement initiatives across multiple functional areas.  Tony is a goal-oriented, energetic team member who works hands-on to promote creative problem solving skills. Comfortable operating at both the strategic and tactical levels, Tony is recognized by TriVista clients for his ability to identify improvement opportunities by applying seasoned analytical, business and lean skills.

The following are a few highlights from a recent TriVista engagement with an industrial manufacturer of large scale wastewater equipment.  Tony was the Lead Consultant:

• Reduced work in-process (WIP) by $250,000
• Increased manufacturing capacity by 50%
• Developed plan to increase manufacturing capacity by 100% without capital investments
• Developed and implemented accurate method of calculating and analyzing overall equipment effectiveness (OEE) for CNC machining centers
• Developed future facility layout resulting in:
  • 74% reduction in manufacturing cycle time
  • 60% reduction in unnecessary product movement
  • 25% increase in manufacturing floor space utilization

Prior to joining TriVista, Tony was Vice President, Quality Assurance and Program Management at Masimo Corporation, where he was responsible for management of quality engineering and supplier quality, and the execution of Lean programs for the global medical device manufacturer.  Prior to Masimo, Tony spent nearly 15 years with Mitsubishi in various engineering management and quality management positions.  In addition to his extensive professional background, Tony is a lead Lean Six Sigma Instructor at the University of California at Irvine, where he has worked with large multinational corporations to teach and certify hundreds of lean and six sigma practitioners.  His work at the University of California has included extensive onsite work at many Fortune 500 corporations, including Northrop-Grumman, Boeing, Sprint, Parker Hannifin and Ricoh.

During his 5 year tenure at Masimo, Tony worked extensively on the production floor to execute Lean and Continuous Improvement projects that resulted in productivity increases of more than 100%, reduced returns by more than 95%, and reduced engineering change orders by more than 65%.

Tony is a Lean Six Sigma Master Black Belt and received his bachelor’s of science in mechanical engineering and his master’s of science in technology management from Southern Polytechnic State University in Marietta, GA. In addition, Tony is a certified PMP (Project Management Professional), a certified ISO Auditor, and an ASQ Certification Instructor.

Recent Experience...

Lean Implementation: Industrial Equipment

TriVista’s client was a private equity owned $65 million manufacturer of industrial equipment. The company was trying to explore ways to increase capacity without adding additional roof-line – max capacity was reached at their existing facility and management didn’t want to relocate. ...FIND OUT HOW.