Steven Forrest

Lean Improvement Specialist

Email: steven_forrest@ncsu.edu | Phone: 704-754-6124

Steven Forrest

Bio

Steven Forrest is a Lean Specialist, also responsible for promoting the Shingo Prize in North Carolina. Steven trains, deploys and consults with industry on Lean and the Toyota Production System, including 5S, value stream mapping, Kaizen, standard work and waste elimination. Steven recently worked with a commercial vehicle manufacturer in High Point and reduced their vehicle work-in-process by 26 units, reduced cell footprint by 800 sq ft, reduced delivery time by ten days, and reduced their manning per vehicle by two. This resulted in an estimated economic impact of more than $2.4 million per year. Steven also enabled an automotive battery manufacturer in Winston-Salem to reduce their lead time on incoming battery orders to one day, reduce WIP inventory of a specific process form 7.5 to 3.5 days, reduce manning per shift by five people, and increase capacity by ten percent. That estimated economic impact was $3.4 million per year. Steven recently worked with a Shingo Prize-winning plant as an examiner at the national level. He works with clients both in state and upon request out of state regarding Shingo engagements: training, coaching, applicant preparation, pre-assessments, etc. focusing of cultural transformation, benchmarking and sustainability. Steven also provides longer term coaching and facilitation in lean transformation projects for businesses in the startup, mid level or advanced stages of their lean journey towards operational excellence. Steven has more than 31 years experience in a variety of manufacturing: OEM dryers, truck and bus, sheet metal fire protection and Tier 1 automotive. He held positions in industrial/process engineering, engineering management, general management, and program management. His experience includes continuous improvement/Kaizen events, product launches, bill of material/routing and labor standards, plant layout, time studies, cellular flow, process mapping, best practices, quoting products, cost estimating, capital equipment procurement, metal fabrication/machining, assembly/test, plant manning and product transfer to international startup plants. Steven has B.S. in Engineering Operations from NC State University with major courses in industrial engineering and business management. He is a senior member of the Institute for Industrial Engineers and a Certified Shingo Examiner.