Brian Sage, PE

Brian is an FTE Senior Advisor with over 26 years of executive leadership in transforming businesses, leading multisite global manufacturing operations, and industrial and manufacturing engineering departments in the transportation, heavy machine, and automotive industries. He has extensive training and experience in the deployment of lean principals. In addition, he has led large-scale lean transformations in direct and consulting roles in OEM and tiered supplier settings and lean deployment in functional groups supporting operations.

Notable experience and accomplishments:

  • Led lean transformation across manufacturing operations and purchasing. 10 plants, 5200+ employees, annual ops budget of $500M+. Led purchasing ($1.2B+), logistics, and inbound freight, as well as Op Ex and Industrial Eng
    • Achieved – 82% reduction in Recordable Incident Rate, Awarded safest plants in the industry by trade group every year.
    • Quality – 73% reduction in initial manufacturing caused warranty.
    • Delivery – Improved On Time Delivery from 88.5% to 98.9%
    • Cost – Improved efficiency from 77.1% to 89.7%
  • Evaluated end-to-end business and coached senior leaders in changing the culture to achieve lean operations on the shop floor, supply chain, manufacturing engineering, purchasing, product engineering, and sales. Businesses range from high speed/low complexity to high complexity/low speed on producing small to large scale (Hydraulic valves, Engines, Large Wheel loaders) in multiple countries and the functional groups that supported them.
  • Led lean transformation of global transmission operations. Annual Budget of over $450M with 2200+ employees, 450 Management employees in 4 countries. 75 – 85 New Product Introduction programs managed through Central ME organization annually with Capital spend of $75 to $100M most years.
  • Led global polymer engineering team as ME. Director, responsible for providing technical support to Product Design, Purchasing, and the Supply base. Global Polymer tooling budgets of approx. $300M annually, Technical Oversight of GM’s Polymer plants worldwide. (6 plants producing 25M parts/year, 12 Parts painting facilities).

Prior to consulting, Brian was Executive Vice President – Manufacturing for Great Dane, Semi Trailers, leading transformational lean applications across multi-site operations and functional groups. At Caterpillar, he coached leadership teams/divisions in lean transformation after leading the global transmission operation for Caterpillar.  He held multiple executive leadership roles in General Motors as M.E Director of the global polymer group, Area Manager – Lansing Car plant – Paint, Director of North American Industrial Engineering -Future product activity, and IE Director for North American Car Group.

Brian holds a Master of Science, Engineering Sciences from the Rensselaer Polytechnic Institute and a Bachelor of Science, Industrial Engineering from Auburn University, and is a registered professional engineer (Industrial Engineering) in GA.