Josh Patterson
Manufacturing Strategy & Lean Deployment
Operational Excellence executive specializing in Lean Management Operating Systems, multi-site transformation, and building cultures of continuous improvement. Author of The CORE 4: A Leader's Operating Framework for Philosophy, Profit, Cash, and Sustainable Growth.
Background
Manufacturing and operations executive with 15+ years of experience leading the transition from decentralized manufacturing to a standardized, centralized Lean operating model in high-mix, component-driven environments. Deep expertise in inventory and material-flow management, applying Theory of Constraints to improve throughput, flow, and revenue generation, and using visual management to drive high-quality, stable operations. Proven leader in multi-level enterprise scheduling to improve transparency, proactive planning, and cross-functional alignment. Known for building strong teams through empowerment, structured training, and clear accountability, ensuring leaders and frontline teams are supported to succeed within their span of control while scaling operational performance.
Career Highlights
Multi-Site Scale Operational Transformation
- Led LMOS deployment across 8 plants and supported regional rollout to 26 sites.
- Led improvement engagements across 12 aerospace suppliers, identifying $3.1M in cost and flow opportunities.
Enterprise Scheduling & Resource Optimization
- Built enterprise scheduling for 80+ projects and 6,000 deliverables, improving cross-functional alignment.
- Deployed advanced scheduling, 30-day forecasting systems, increasing revenue 67% ($900K → $1.5M) in four months.
Lean Systems & Daily Management Implementation
- Created the LMOS blueprint approved for global rollout to 60 sites and supported deployment at 26 locations.
- Trained and coached 50+ plant leaders in LMOS, Tier routines, LSW, and visual management.
Throughput & Productivity Acceleration
- Increased production throughput 94% (90 → 175 units/shift), with Theory of Constraints, Single Piece Flow, and flow redesign.
- Boosted engineering throughput 346%, unlocking $10M+ in capacity with scheduling and internal customer communication.
Strategic Revenue Growth & Business Enablement
- Enabled $9M annual revenue with only $100K capex by removing production constraints and raising throughput.
- Improved sequencing, labor planning, and material flow to support revenue growth from $120M to $170M.
Data Architecture & Analytical Automation
- Partnered with FP&A to build Qlik dashboards for 27M+ records, eliminating 36 hours/year of manual work.
- Streamlined big-data workflows into decision-ready outputs, enabling $300K savings, reducing non-value-added effort 84%.
Professional Experience
Regional Operations Manager
Site Leadership & Lean Scheduling — $15M Sunroom & Pool Enclosure Manufacturer
Oversaw operations across four Florida markets, aligning installer capacity, scheduling, workforce readiness, and Tier routines to support $15M+ annual revenue.
- Deployed advanced scheduling and 30-day forecasting systems, increasing revenue 67% ($900K → $1.5M) in 4 months
- Directed monthly P&L performance while enhancing safety, inventory readiness, and quality systems
- Created installation capacity planning to meet forecasted demand and maintain consistent training and coaching
Director of Scheduling & Planning
Enterprise Scheduling & Cross-Department Leadership — $70M Custom Architectural Glass Systems
Directed the full 360° scheduling process—from Estimating through Engineering, Fabrication, Staging, Delivery, and Field Execution.
- Translated the CEO's vision into a scalable enterprise scheduling system overseeing $70M in active projects
- Led and coached 4 Project Managers and cross-functional teams overseeing 80+ projects and 6,000 deliverables
- Drove a 346% increase ($10M) in engineering throughput through capacity planning and critical path scheduling
Lean Manufacturing Area Manager
High-Volume Production & Plant Leadership — $150M Residential Window & Door Manufacturer
Directed multiple production lines and 150+ employees deploying Lean, TOC, TPM, 5S, and Leader Standard Work.
- Increased throughput 94% by raising output from 90 to 175 units per shift through flow redesign
- Enabled $9M annual revenue uplift with only $100K capex by increasing weekly throughput 2,000 → 3,000 units
- Achieved 700+ accident-free days by strengthening safety culture with LSW and TPM practices
- Boosted revenue from $120M to $170M by optimizing sequencing, labor planning, and material-flow processes
Lean Transformational Deployment Leader
Enterprise Lean Transformation & LMOS Deployment — $2B Global Door Manufacturer & Distributor
Led enterprise Lean transformation and deployment of Masonite's Lean Management Operating System (LMOS).
- Developed LMOS core routines at 8 plants, supporting 30+ leaders
- Selected by the SVP over MBBs to help Regional/Site Leaders restart LMOS and scale to 200 employees in 3 weeks
- Designed LMOS training for 50+ manufacturing leaders to begin deployment ahead of implementation support
Supplier Developer / Lean Consultant
Supplier Development & Lean Systems Consulting — $15B Aircraft Engine Manufacturer
Led supplier performance improvement and Lean transformation initiatives across the global aerospace supply chain.
- Identified $3.1M in performance and cost-reduction opportunities across 12 suppliers
- Delivered 8 Lean workshops to strengthen supplier capability in waste reduction and flow control
- Created a supplier scoring model for 35K products across 300 suppliers
Continuous Improvement Manager
Continuous Improvement Leadership & Lean Training — $500M Aircraft MRO Provider
Led Lean transformation and Six Sigma initiatives across heavy aircraft maintenance operations.
- Delivered $2.3M savings by reducing 40% NVA through a major United Airlines Six Sigma Green Belt project
- Designed and optimized 400K sq ft of hangar layouts, eliminating 30% NVA
- Achieved 80% cycle-time reduction by redesigning workflows and eliminating operational delays
F-15 Crew Chief & FAA A&P Mechanic
Military Aviation & Civil Aircraft Maintenance
- USAF Honor Graduate and "Best of the Best" F-15 fighter out of 60 aircraft in 1996, Honorable Discharge in 1999
- Civil aircraft engine run and taxi, experienced on Boeing 767, 757, 737, 727, MD-80, Gulfstream G5, CRJ-200 aircraft
Certifications & Education
Black Belt
Operational Excellence
Powerplant License
Pilot License
Aviation Mgmt
(In Progress — 2027)
License
Key Books for Guidance
Lean Operating System
Increase Throughput
Change Management
14 Principles
Let's Connect
Whether you're looking for speaking, consulting, or just want to talk operations—I'd love to hear from you.