Building Sustainable
Operational Excellence

I work with individuals and organizations navigating improvement projects at any stage. I offer business operations coaching and free Lean Six Sigma training.

Jerry DeFranco
Jerry DeFranco
Lean Six Sigma Master Black Belt (LSSMBB)· Project Management Professional (PMP)· PMI Agile Certified Practitioner (PMI-ACP)· Professional Scrum Master (PSM I)· Professional Scrum Product Owner (PSPO I)· Microsoft 365 Fundamentals (MS-900)· Cybersecurity Fundamentals (SC-900)· Azure Fundamentals (AZ-900)· Artificial Intelligence Fundamentals (AI-900)· Doctor of Business Administration Candidate· Master of Science in Organizational Leadership (MSOL)· Bachelor of Arts, Liberal Arts· Associate of Applied Science, Technical Studies· Lean Six Sigma Master Black Belt (LSSMBB)· Project Management Professional (PMP)· PMI Agile Certified Practitioner (PMI-ACP)· Professional Scrum Master (PSM I)· Professional Scrum Product Owner (PSPO I)· Microsoft 365 Fundamentals (MS-900)· Cybersecurity Fundamentals (SC-900)· Azure Fundamentals (AZ-900)· Artificial Intelligence Fundamentals (AI-900)· Doctor of Business Administration Candidate· Master of Science in Organizational Leadership (MSOL)· Bachelor of Arts, Liberal Arts· Associate of Applied Science, Technical Studies·

Teaching Philosophy

Learn by Doing. Tailored to You.

Adult learners need relevancy and interest. Every lesson, tool, and exercise is built around real problems in your organization.

01

Relevancy Over Curriculum

Adult learners disengage from abstract concepts with no connection to their daily work. Every lesson is anchored to real problems in your organization, using your data, your processes, and your people as the classroom.

02

Tailored to Your Organization

The Toyota Production System cannot be copied and pasted into another organization. The philosophy can. Drawing from Lean, Six Sigma, Theory of Constraints, Agile, and DevOps, I build training that fits your culture and your constraints.

03

Sustainability by Design

Most improvement programs collapse because they were never woven into how the organization actually operates. I design for the people who will carry the work forward long after the training ends.

04

Learning Through Experimentation

Real learning happens through cycles of action and reflection. The Plan-Do-Check-Act cycle is more than a quality tool. It is the structure of how adults build lasting competence. You plan a change, try it, study the result, and act on what you learn. Each cycle deepens understanding in ways that reading alone never can.

Interactive Learning Tools

Learn by Doing: Free Tools and Simulators

These tools bring operational excellence concepts to life through hands-on simulation and calculation. Each one is built for adult learners who learn by doing.

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Hidden Revenue Calculator

Map the eight DOWNTIME wastes across your operation and quantify the revenue consumed by non-value-added activity every day.

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Process Mining App

Visualize how work actually flows through your organization by analyzing event log data to reveal bottlenecks, rework loops, and process drift.

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Process Mapping App

Build structured process maps that document the current state, identify waste, and form the baseline for targeted improvement efforts.

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Value Stream Mapping App

Create end-to-end value stream maps showing material and information flow, cycle times, and the ratio of value-added to non-value-added time.

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Theory of Constraints Simulation

Run the Goldratt Dice Game to experience how statistical fluctuations and dependent events create system-wide bottlenecks regardless of individual effort.

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Factory Physics Simulation

Use the Penny Fab model to explore the relationships between work-in-process, throughput, and cycle time as described in Hopp and Spearman's Factory Physics.

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Control Chart Builder

Paste your data to generate a Statistical Process Control chart with control limits, spec limits, and a bell curve. Separate special cause variation from common cause noise instantly.

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Case Studies

Learning from the Field

Each case study documents the application of tailored operational excellence methodology across real organizations and real constraints.

Naval Aviation

Building a Lean Six Sigma Certification Program on an Aircraft Carrier

Establishing a formal continuous improvement program from scratch aboard a commissioned naval vessel requires navigating rigid command structures, competing operational priorities, and a workforce trained for precision over process awareness.

Read the full case study
Manufacturing

Failure Modes and Effects Analysis for a Submarine Electronics Manufacturer

A submarine electronics manufacturer needed a structured approach to identifying failure risks across a complex assembly process where defects carry mission-critical consequences. FMEA surfaced the highest-priority failure points and drove targeted preventive action.

Read the full case study
Aerospace

Value Stream Mapping for a Satellite Manufacturer

A satellite manufacturer was struggling with long lead times and unclear handoffs between production stages. Value stream mapping exposed the hidden delays between value-added steps and became the foundation for a multi-phase improvement roadmap.

Read the full case study
Manufacturing

Root Cause Analysis for Manufacturability and Producibility

Design and production were repeatedly creating rework cycles that traced back to the original engineering specifications. Root cause analysis identified the gap between what the design required and what the production floor could reliably deliver.

Read the full case study
Executive Planning

Developing Executive Planning Sessions for the U.S. Navy

Senior naval leadership needed a structured annual planning process that aligned strategic priorities with operational execution across multiple commands. Hoshin Kanri provided the framework for cascading leadership intent into measurable action at every level.

Read the full case study
MRO Operations

Buffer Management for Maintenance Supply Chains

A maintenance operation was losing readiness time to parts shortages that traditional inventory models failed to anticipate. Theory of Constraints buffer management replaced reactive ordering with a demand-driven system tied to actual consumption rates.

Read the full case study

Certifications & Education

My Certifications and Academic Background

Every credential below was earned in the field, not the classroom. Here is what I hold and what it means in practice.

Lean Six Sigma Master Black Belt (LSSMBB) Villanova University  |  Expires 2027 The highest practitioner-level certification in Lean Six Sigma. It qualifies me to design, lead, and teach improvement programs at the enterprise level across any industry.
Project Management Professional (PMP) PMI  |  Expires 2027 The global standard for project management professionals. I use it to structure improvement initiatives with clear scope, timelines, and accountability from day one.
PMI Agile Certified Practitioner (PMI-ACP) PMI  |  Expires 2027 Agile certification covering Scrum, Kanban, Lean, and XP. I use it to integrate iterative project management with the iterative nature of Plan-Do-Check-Act cycles from Shewhart and Deming.
Professional Scrum Master (PSM I) Scrum.org Professional Scrum Master certification validating fluency in Scrum theory, practices, and team facilitation for iterative delivery environments.
Professional Scrum Product Owner (PSPO I) Scrum.org Professional Scrum Product Owner certification focused on maximizing value delivery and managing product backlogs in Agile environments.
Microsoft 365 Fundamentals (MS-900) Microsoft  |  2024 Microsoft 365 Fundamentals covering cloud productivity tools, collaboration platforms, and security basics across the Microsoft ecosystem.
Cybersecurity Fundamentals (SC-900) Microsoft  |  2024 Microsoft Cybersecurity Fundamentals covering core security, compliance, and identity concepts across cloud and hybrid environments.
Azure Fundamentals (AZ-900) Microsoft  |  2024 Microsoft Azure Fundamentals covering cloud concepts, core Azure services, and the basics of cloud architecture and deployment.
Artificial Intelligence Fundamentals (AI-900) Microsoft  |  2024 Microsoft Artificial Intelligence Fundamentals covering machine learning concepts, responsible AI, and how AI services are applied in real-world workflows.
Doctor of Business Administration Candidate Florida Institute of Technology  |  Expected 2028 Doctoral research in Business Administration at Florida Institute of Technology, with dissertation work focused on organizational performance and operational effectiveness.
Master of Science in Organizational Leadership (MSOL) Excelsior University  |  2024  |  Concentration in Innovative Technology and Data Analytics A graduate degree in organizational leadership grounding my teaching practice in how organizations change, learn, and sustain new behaviors.
Bachelor of Arts, Liberal Arts Excelsior University  |  2021  |  Concentration in History A broad academic foundation developing the analytical and contextual thinking that shapes how I approach complex organizational problems.
Associate of Applied Science, Technical Studies Excelsior University  |  2011  |  Concentration in Calibration and Instrumentation A technical degree reflecting the precision engineering roots that underpin my approach to measurement and process control.

Professional Journey

Where the Work Was Done

Jerry DeFranco

Jerry DeFranco  |  LSSMBB, PMP, PSM I, PSPO I
Melbourne, Florida

2024 – 2026

Principal of Continuous Improvement

L3Harris Technologies  |  Palm Bay, FL

Led rapid improvement events and analysis workshops across global space and mission systems, driving $158.7M in annualized savings. Facilitated rapid improvement workshops for a satellite manufacturer that generated $4.1M in actualized savings. Trained 60 students in formal Lean Six Sigma coursework whose improvement portfolios produced $8.1M in validated savings. Developed Palantir Foundry applications to automate bottleneck identification and operational reporting using manufacturing ERP data.

2024

Solutions Delivery Manager

Microsoft  |  Remote (DoD SkillBridge)

Led Azure migrations and AI application development for pharmaceutical clients as part of a DoD SkillBridge internship for transitioning veterans. Mentored other veterans in civilian transition with career-building certifications by running test prep workshops for Microsoft, Scrum Alliance, Project Management Institute, and Lean Six Sigma authorities.

2020 – 2024

Director of Continuous Improvement

U.S. Navy  |  Norfolk, VA (USS Gerald Ford)

Established the Lean Six Sigma program on the Navy's newest aircraft carrier, earning a perfect score on its first compliance audit. Led six CI directors across three carriers and one shore facility. Certified 500+ belts and reduced repair cycle times by up to 90%.

2017 – 2020

Flight Line Manager

U.S. Navy  |  San Diego, CA

Cut the aviation maintenance backlog at a helicopter squadron by 50% using SQL analytics to identify bottlenecks in repair supplies, personnel, and aircraft scheduling, feeding into targeted Lean Six Sigma projects. Led 30 technicians across four shifts while maintaining 100% on-time flight operations.

2010 – 2017

Director of Training and Development

U.S. Navy  |  Yokosuka, Japan  |  Jacksonville, FL

Developed and administered the Navy's Advanced Skills Management digital credentialing platform for naval aviation maintenance. Coordinated migration of 9,000+ credentials across three aircraft carriers during a complex hull-swap.

2004 – 2010

Early Navy Career

U.S. Navy  |  Multiple Locations

Served across nuclear propulsion, avionics repair, hydraulics, calibration, and flight line supervision. Started in the Naval Nuclear Power Program before transitioning to naval aviation maintenance, building a technical foundation across multiple engineering disciplines.

The Mission

The Pressure to Conform and the Freedom to Innovate

Too many improvement professionals apply methodology the textbook way because institutions, accreditation bodies, and industry norms create pressure for organizations to look the same. That conformity is precisely why so many programs fail to sustain.

The most competitive organizations in the world are taking the core philosophies, tools, and techniques from multiple disciplines and building something that fits their culture, their constraints, and their people. They move faster. They sustain longer. Most of them are not calling it Lean or Six Sigma at all.

This is how every major improvement methodology was built in the first place. The George Group took tools from multiple disciplines and assembled what we now call Lean Six Sigma. Toyota built their production system out of necessity, working within the severe resource and capital constraints of post-World War II Japan where waste was not an option and every part, every motion, and every minute had to count. Six Sigma came from Motorola's engineering culture, not a textbook. Agile emerged from software teams who learned from manufacturing and adapted those principles to fit how they actually worked. DevOps followed the same path, borrowing from Lean and Agile and reshaping them for continuous delivery pipelines. Every methodology that has lasted was built by practitioners who tailored ideas to their context, not by organizations that copied someone else's framework wholesale.

"I believe in American know-how and tenacity. We used to be industry leaders of the world. We can be again."

Reshoring manufacturing, building domestic workforce capability, and influencing policy through research are not abstract goals. They are the reason I build training programs, write case studies, and invest in tools that make operational excellence accessible to every organization. The goal is straightforward: bring jobs back to the United States and rebuild a nation that makes things again.

Get In Touch

Let's Design Something That Works for Your Team

Start a Conversation

Every engagement starts with understanding your organization. Reach out directly and we can talk through what you are trying to accomplish.

I work with manufacturers, health care providers, organizations of all sizes, and students. Custom training design, workforce development, and operational advisory work are all on the table.

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Melbourne, FL