Brian Kirby

VP of Operations

Full Background

Six Sigma Green Belt Certified, achievement-focused, and self-motivated, Brian is an operations directive professional with over 20 years of hands-on experience in all facets of materials, planning, logistics and plant production. His proven track record of accomplishments includes impressive yields in cost-reduction and volume increase.

Brian is a known change agent with expertise in troubleshooting and implementing quality improvement processes and a willingness to go the extra mile. His areas of expertise include project management, production planning, scheduling, purchasing, and lean manufacturing.

As an Executive Consultant and VP of Operations with Cornerstone Consulting, Brian has helped clients by improving throughput in four areas by over 133%, changed the flow of the plant and opened up 30% floor space, and improved on time delivery to all customers 98%. For another client, Brian improved the plant’s throughput by 53% and negotiated two new contracts that generated a savings of $475K. In addition, Brian has acted as COO over production, quality, and materials—reducing 24K past-due parts for production in two months and reduced an additional 38K past-due service orders within six months.

Prior to joining Cornerstone Consulting, Brian had a career with Lear Corporation. In his most recent role as Production and Plant Manager, Brian oversaw over $200M in annual sales and maintained world class housekeeping. He also supported the U251 launch program, and as Aftermarket Parts Manager, improved the delivery rating from 72% to 98.7% over 12 months. His other achievements include lowering RPPM’s from 1180 in 2003 to 37 in 2004 with Zero QR’s, participating in Kaizen workshops, and supporting the Peugeot 206 launch.

As Materials Manager over Lean Manufacturing and Continuous Improvement at Lear, Brian managed inventory for JIT facility with monthly inventory levels exceeding $200M, conducted bi-annual physical inventory and reconciliation, and achieved a reduction in inventory levels by $4.2M to realize a total freight savings of $1.6M. While in this role, Brian also negotiated a freight reduction resulting in over $1M savings, maintained BOMs, ran AS400 and EDI systems, and improved aftermarket service ratings from four to one on GM service.

Brian received his Survey of Quality Tools certificate through Lawrence Technological University, 8D Problem Solving with Team Building certificate with Eastern Michigan University, and Six Sigma Green Belt through the Lear Corporation. He also received training in CMMS3 Ford Production Suppliers, DDL Ford Customer Service Division, and Business Management at Northwood University.