Terrence J Kosky
Supply Chain Management Consulting
Terrance has 25 + years experience implementing complex business process transformations throughout the supply chain focusing on revenue enhancement, cost reduction and performance improvement. His experience includes supply chain strategy, sales & operation planning, strategic sourcing, lean manufacturing, and distribution in a range of companies and industries both domestic and international. The supply chain transformations have been supported by his design and implementation of global ERP systems including Oracle, SAP, and JD Edwards, specifically in demand/supply planning, production planning, and flow/discrete manufacturing systems. He is Oracle Certified in Value Chain Planning processes and system implementations.
Mr. Kosky is an independent consultant whose clients have included: Motorola, Master Lock, Rheem Manufacturing, Cummins, Tecumseh Products, Ford Motor Co., DaimlerChrysler, General Motors, Samsung Motors, Volkswagen of America, Trico Wipers, SPX Industries, American Axle and Manufacturing, Snap-On Tools, Delphi, Lear, Visteon, Valeo, Masco, NSK, TI Automotive, Tomkins UK, Allied Signal, Arvin-Meritor, Caterpillar, Nike, Delta Air Lines, Pitney Bowes, Nabisco, John Deere, Bacardi, Liz Claiborne, Epson of America, Motor Coach Industries, NASA Space Program and Governmental Service Agency. Previously, he held Director- level positions in PricewaterhouseCoopers Automotive and Industrial Product Performance Improvement Practice, Coopers Lybrand Automotive Practice, KPMG Advisory Services and Accenture Consulting.
Selected client accomplishments include:
Assessment of multi-divisional planning and supply operations identifying operational issues and root causes affecting process efficiency; implementation of action plans resulted in manufacturing throughput improvement of 40% and inventory reductions of 28%.
Developed global supplier collaboration using VMIs to improve inventory availability, supplier commits to forecast, and supplier on-time performance in global hub &spoke operations.
Implemented global Sales and Operation Planning processes for business units synchronizing global production capacity with 18-month rolling demand plan to maximize capacity utilization and margin contribution. Results include: 30% reduction in inter-company inventory; increased capacity utilization to 85-90%, and schedule attainments averaging 95%.
Implemented Flow Manufacturing in 8 production lines including recalculation of variable lead times to rebalance lines. Results: 28% improvement in production throughput and WIP inventory reduction
Implemented Lean Six Sigma in a $6.0B US Tier I auto manufacturer to reduce lead times, convert to flow manufacturing, and improve first-run yields using Oracle Flow Manufacturing and MRP applications. Lean Six Sigma programs resulted in: reduced manufacturing lead times by 32%, inventories by 41%, manufacturing overhead and quality costs by 28%. Project realized savings of $2.6M annually.
Implemented supply chain planning processes (S&OP) to effectively match demand to supply to obtain target operating margin improvements of 25%+.
Demonstrated ability to resolve production and supply issues, identify root causes, and drive measurable performance improvement through Six Sigma Lean initiatives.
Mr. Kosky is APICS certified in Production and Inventory Management, and is a Lean Six-Sigma Black Belt. He holds a MBA in Finance and Operations from the University of Detroit/Mercy and undergraduate degree in Accounting from Wayne State University.