Brian is available for hire

Brian Terry

Verified Expert in Project Management

Project Manager

Westminster, SC, United States

Toptal member since September 16, 2024

Expertise

Virtual Project Management Lean Project Management

Bio

Brian has experience leading process improvement across diverse industries, including consumer products, automotive, aerospace, food and beverage, industrial products, and military sectors. He has successfully delivered quality, continuous improvement (CI), Six Sigma, Lean manufacturing, and 5S programs. Having collaborated with domestic and international teams in over 20 countries, Brian has delivered over $2 billion in NPI launches, $200 million in investments, and $40 million in savings.

Expertise

Lean Manufacturing
Manufacturing
Operational Excellence
Project Management
Quality Management Systems (QMS)
Relationship Building
Six Sigma
Teamwork

Work Experience

Contractor

2023 - PRESENT

Metaops

Built leading facility and multi-facility process, quality, and continuous improvement (CI) transformations.
Worked across multiple industries, spanning quality management systems (QMS), CI, Six Sigma, Lean manufacturing, 5S, and value stream mapping.
Focused processes on value add, technology change, and process gains for cross-functional multi-cultural teams in product, process, and build lifecycles.

Contractor

2009 - PRESENT

CIQ Systems

Handled QMS documentation, system building and retooling, and standard work architecture.
Worked on overall equipment effectiveness, value stream mapping, CAPA management, analytics, and problem-solving tasks and acted as a Kaizen event practitioner.
Led and supported over 150 audits under ISO 9001 and AS9100 requirements.
Identified more than $200 million in business value savings.

Lean Six Sigma Black Belt

2024 - 2025

Schneider Electric SE - Main

Achieved an MCC-ETO Pod-3 reduction of 95% in confirmed "Waiting on Materials" combined occurrences/day in MPH by improving the Water Spider (rack) and Kitting (cart) delivery/store systems through Scrum Sprint(s).
Met KPI requirement for the project on Pod-3 in the 60-day window of sprint 1.
Completed multiple unit build and unit wiring workstation designs and new optimized Pod-3 unit and wiring build layout designs given to manufacturing engineering.
Worked on a new optimized Pod-3 unit and wiring build layout designs that saved 600+ sf of floor space and doubled capacity.

Change Leader

2021 - 2023

Sandvik

Acted as the site enterprise business process (EBP) system leader for production and finance, handling the end-to-end implementation of SAP.
Worked as a training lead, handling program development, execution, and sustainability for all local enterprise-level applications and implementations in Lean, Six Sigma 5S, and Industry 4.0.
Handled 5S, value stream mapping, and SMED events as a production unit lead, working on program definition, training, and implementation.
Collaborated as an editor and writer for a monthly periodical for change management communication and enterprise-wide digitalization progress articles highlighting local success stories.

Six Sigma Master Black Belt

2017 - 2021

SKF

Implemented a contract measurement system readiness program, resulting in more than $336,000 in annual savings.
Handled SKF's problem-solving and core tools, mentoring 11 Six Sigma Green Belts and 30+ White Belts.
Trained over 1,000 employees, staff, vendors, and vendor representatives in Lean Six Sigma tools, systems, processes, and applications.
Collaborated with the core team to secure certified NADCAP customer requirements for heat treatment and chemical processing.
Co-led and audited two plant conversions from the AS9100 Revision C and ISO 9001 standards to the updated AS9100 Revision D standard for dual sites.

Contract Manufacturing Auditor

2016 - 2016

Collins Aerospace

Conducted the vacuum forming process review for the F-35 pilot helmet product audit.
Performed the vacuum forming product dimensional review for the F-35 pilot helmet product audit.
Investigated various end-user delivery concerns to optimize processes.

Head of Business and Operational Excellence

2014 - 2015

Qatargas Operating

Designed and implemented an operational excellence framework and system for the industrial cities directorate.
Managed operational excellence support staff with over seventy projects in progress or under evaluation and a potential of more than $300 million in value and efficiency gains over the next two years.
Collaborated with KPMG to identify high-return project potential within the directorate.
Conducted 12 major Kaizen events with all cross-functional teams at all levels within the directorate.

Corporate Quality Engineer | Quality Program Manager

2010 - 2014

Starbucks

Acted as the subject-matter expert for quality management audits and single-serve manufacturing operations.
Led international supply chain co-manufacturing quality programs across the Asia Pacific region, the Americas, Europe, the Middle East, and Africa.
Contributed to quality system assimilation for 3rd-party acquisitions, including Evolutions, La Boulange, and Teavana.
Directed the operational quality function for ongoing strategic product launches within co-manufacturing operations.
Managed the quality and manufacturing aspects of the successful launch of over $2.2 billion in combined initial-year product sales.

Project History

Government Contract Rescue Through a QMS and Relationship Building

Saved a startup's government contract by formalizing and implementing a QMS, aligning the ERP system, and developing and nurturing relationships with government officials.

A startup facility faced the potential loss of a new government contract extension due to its lack of a formalized QMS and a relationship with the Defense Contract Management Agency (DCMA), jeopardizing a $1 billion military contract for a new military vehicle.

Over 12 months, I formalized and implemented a QMS, aligned the ERP system, developed and nurtured relationships with government officials, and ensured contract compliance to restore confidence in fulfilling the contract requirements. As a result of my efforts, the contract was saved and 27% more units were added to the initial 5,200-unit contract. This saved over $700 million in potential losses.

Tug Fleet Reduction Project

Participated in negotiations and prepared cost and benefit analyses and data analyses that helped the leadership reduce tug groups from four to three, reducing total costs by $153 million.

A 10-year transportation contract controlling the capacity of one of the most impactful ports in the energy world required a decision on whether to give back a tug group added a decade earlier. With data and benefit justifications, my team highlighted a pathway that gave the leadership confidence to "save face" internally by reducing a heavily lobbied resource increase from the previous decade's contract negotiations.

This project involved heavy negotiation, cost and benefit analysis, data analysis, teamwork, and communication. As a result, a contract was signed, and the number of tug groups was reduced from four to three, which reduced total costs by $153 million.

Quality Operations Streamlining for Bearing Manufacturer

Transitioned 26 employees to higher-impact roles, saving $800,000+ annually, achieved a 100% ROI on the annual cost savings of $336,000, and enhanced operational efficiency and strategic utilization of highly skilled personnel.

A bearing manufacturer faced challenges in gauge management across two facilities. An overwhelming 26-member quality department handled daily measurements, maintenance, and validation of 2,000+ gauges critical for meeting customer requirements.

I conducted a cost and benefit analysis and strategically transferred all affected employees to more impactful positions without layoffs. In addition, I outsourced maintenance of the measurement system, meticulously managing the entire process from writing contracts to ensuring ISO 17025 and AS9100 certification compliance. I transitioned 26 employees to higher-impact roles, saving over $800,000 annually. As a result, the company achieved a 100%+ ROI on the annual cost savings of $336,000 and the operational efficiency and strategic utilization of highly skilled personnel was enhanced.

Education

2019 - 2019

Master's Certificate in Lean Manufacturing

University of Michigan - Ann Arbor, MI, USA

1994 - 1994

Master's Degree in Technology

Western Carolina University - Cullowhee, NC, USA

1991 - 1993

Bachelor's Degree in Manufacturing Engineering Technology

Western Carolina University - Cullowhee, NC, USA