I work with individuals and organizations navigating improvement projects at any stage. I offer business operations coaching and free Lean Six Sigma training.
Teaching Philosophy
Adult learners need relevancy and interest. Every lesson, tool, and exercise is built around real problems in your organization.
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.
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.
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.
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
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.
Map the eight DOWNTIME wastes across your operation and quantify the revenue consumed by non-value-added activity every day.
Launch ToolVisualize how work actually flows through your organization by analyzing event log data to reveal bottlenecks, rework loops, and process drift.
Launch ToolBuild structured process maps that document the current state, identify waste, and form the baseline for targeted improvement efforts.
Launch ToolCreate end-to-end value stream maps showing material and information flow, cycle times, and the ratio of value-added to non-value-added time.
Launch ToolRun the Goldratt Dice Game to experience how statistical fluctuations and dependent events create system-wide bottlenecks regardless of individual effort.
Launch SimulationUse 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.
Launch SimulationPaste 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.
Launch ToolCase Studies
Each case study documents the application of tailored operational excellence methodology across real organizations and real constraints.
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 studyA 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 studyA 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 studyDesign 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 studySenior 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 studyA 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 studyCertifications & Education
Every credential below was earned in the field, not the classroom. Here is what I hold and what it means in practice.
Professional Journey
Jerry DeFranco | LSSMBB, PMP, PSM I, PSPO I
Melbourne, Florida
2024 – 2026
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
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
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
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
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
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
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
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.