Bob Mallard
Partner | Lean Manufacturing & Factory Turnaround
More than 40 years of manufacturing experience, including factory management, Lean manufacturing, and operational turnaround.
Bob Mallard is a partner at Manufacturing Transformation Group (MTG) with 40+ years of manufacturing experience. He brings firsthand experience running manufacturing businesses to his consulting work.
He specialises in Lean manufacturing, Gemba kaizen and operational turnaround. His strength lies in observing how a factory actually operates, spotting problems others may overlook, and identifying where improvements are needed.
Example Manufacturing Projects & Results:
Five factories consolidated into one
Bob consolidated five electronics manufacturing facilities, two in the US and three in China, into a single operation. The business went from break-even to 25% EBITDA.
31% productivity improvement
At a Chinese sporting goods supplier, Bob increased productivity by 31%, reduced headcount, and improved quality, saving $3 million.
New factory achieves 40% higher productivity
He led the development of a new manufacturing facility that achieved 40% higher productivity while requiring 50% less labour than the previous factory.
$300,000 in annual savings
Led operational improvements at a seafood processing business, generating $300,000 in annual savings.
Returning a business to profitability
Turned around a fishing reel company's operations, restoring profitability for the first time in five years.
A Career Built in Manufacturing
Bob's career includes senior manufacturing roles, factory ownership and extensive international experience.
At Michelin, he progressed from line supervisor to wire factory manager. He also worked on a global ERP implementation involving Canada and France.
Bob has owned and managed a foundry and operated a profitable trading company in China, primarily dealing in forged and cast products.
His manufacturing experience spans the United States, Canada, China and Europe, across industries including:
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Automotive and electronics
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Consumer products and sporting goods
- Industrial gases
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Forging, casting and metal fabrication
Education
Western University
Operations and Supervision
Conestoga College
Industrial Engineering