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Robert
K. Hall
Mr. Hall is a manufacturing executive with over 15
years of multi-site management and profit and loss
experience, including five years at the vice-president
level and three years as general manager. He
has an extensive 12-year background in lean manufacturing
and has markedly increased profits and efficiency
for metals, plastics, electronics, and automotive
manufacturers.
Mr. Hall's achievements include leading a process
that helped increase operating profit by $229M and
organizing more than 800 high-performance lean improvement
teams in 120 plants worldwide. He has served
as a lean manufacturing improvement consultant to
a wide variety of companies including Allied Signal,
Ford Motor Company, Vickers, Ocean Spray, Chesterton,
Badger Meter, Holset Engineering, Rome Strip Steel,
Ciba Corning Diagnostics, Boston Scientific/Symbiosis,
Dial, Solvay Automotive, Pinkerton, UVEX, Cabletec,
Miller, Texas Foundries, John Deere, Joy Mining Machinery,
Norcross Safety Products, Libbey, Specialty Engraving,
Moen, Tempel Steel, Wright Packaging, Eimo, IR Bobcat,
TST, Baxter, Flowers Foods, Neptune Technology, Toll
Brothers, Electrolux, and Texas Instruments.
As vice president of operations and lean manufacturing
for Rexnord unit of Invensys (a global leader in the
automation and controls industry), Mr. Hall was responsible
for implementing lean manufacturing at 30 plants with
6000 employees in the United States and Europe. He
increased operating profit by $18M, initiated 542
Kaizen teams, developed 36 Six Sigma black belts,
and trained over 1000 employees in lean manufacturing
strategies. As vice president of operations for appliance
controls unit of Invensys, he increased operating
profit by $6M, improved customer quality by 71 percent,
and increased on-time delivery from 82 to 94 percent.
Previously Mr. Hall was vice president of supply chain
management at InterMetro Industries, the largest worldwide
manufacturer of wire, sheet metal, and plastic shelving
and carts. His introduction of a continuous
improvement initiative and creation of 30 high-performance
teams increased operating profit by $7M and reduced
manufacturing cycle time by 83 percent (from six days
to one day). In addition, Mr. Hall led
the corporation through its first successful ISO 9001
registration audit.
Earlier in his career, Mr. Hall held several management
positions at American National Can, one of the world's
largest can, bottle, and plastic packaging manufacturers. As
manager of time-based strategy, he increased profits
by $198M in three years and achieved a $700,000 annual
cost savings by reducing setup time from two hours
to 30 minutes. He also trained 3000 executives,
managers, and hourly personnel in lean manufacturing,
just-in-time techniques, setup reduction, total productive
maintenance, and process mapping. As general
manager of the Apache Control Systems Division, Mr.
Hall led successful turnaround that returned the division
to profitability after six consecutive years of losses. He
delivered a $34,000 profit within six months on $1.8M
in annual sales, built revenues to a record $2.1M
with $225,000 operating profit, and reduced inventories
by 42 percent.
Education
Master of Business Administration, University of Chicago,
Chicago, Illinois
Bachelor of Science, Industrial Engineering, Purdue
University, West Lafayette, Indiana
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