Principal Consultant
TERRY S. MERCER, Lean and Six Sigma


Terry Mercer is a seasoned consultant, manufacturing executive, and project manager with over 20 years of industrial experience and 12 years of consulting in a variety of industrial, distribution, and medical environments.  He has managed business turnarounds and start-ups and led a number of organizations through significant restructuring using Lean and Six Sigma Methods.  With skilled leadership, Terry helps organizations and project teams identify significant profit building and efficiency opportunities. He is adept at developing and implementing robust solutions to achieve result in new levels of performance improvement and revenues achievement.

He is expert in Lean Manufacturing, Lean Six Sigma techniques, shop floor control systems, performance measurement, factory scheduling systems, ERP implementations, and supply chain issues.  He has served 100- to 1,500-person organizations in both consulting and executive roles throughout a variety of industries, including medical equipment, pharmaceuticals, distribution, metal working, injection molding, newspapers, equipment assembly, process industries, and PCB assembly with aerospace and electronics firms.

Highly experienced as a former VP of operations, general manager, and senior consulting executive, examples of Terry’s accomplishments include:

• Turning around a $20-million semiconductor equipment business.  He achieved 30% sales growth, eliminated a 6 week backlog of past-due shipments, reduced lead times from 18 to 3 weeks, and introduced a new generation of instruments. (Refer to this documented case study in the Handbook of Supply Chain Management. by JB Ayers)
• Developed and implemented an improvement plan for a $100-million contract assembly and distribution warehouse that included a new distribution warehouse layout that resulted in a 40% increase in capacity and a 50% increase in picking and packing productivity. 
• As project manager, led a Lean conversion at a $150 million PCB assembly start-up, utilizing Blitz Kaizen events.  Revised the Kanban strategy, plant layout, and shop floor scheduling practices, and instituted 5S methods, resulting in 27% productivity and 16% throughput increases.
• Reduced $3.5 million in annual operating expenses for a medical equipment manufacturer by consolidating a $25 million product line in a sister facility, including consideration of offshore manufacturing options.

Terry holds a bachelor of science in electrical engineering from Carnegie Mellon University and an masters of business administration from Cornell University.

Go back to "Our Team"