Perry Hall

Perry has over 30 years of experience in lean manufacturing, including 12 years at Toyota Manufacturing in Georgetown, Kentucky, where he managed production operations. His expertise spans traditional continuous improvement, interim leadership, plant relocations, production line ramp-ups, assembly line layout design, and workflow optimization. He has demonstrated a unique ability to balance strategic planning with on-the-floor execution, driving sustainable improvements across diverse industries.

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Perry has designed and optimized assembly line layouts to enhance flow efficiency, reduce cycle times, and support ergonomic principles. His efforts have enabled companies to maximize production capacity while maintaining high safety and quality standards. He has also streamlined workflows to align operations with lean principles, ensuring smooth transitions during new line launches and plant relocations.

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In addition to his technical skills, Perry has developed and delivered extensive training materials tailored to meet the needs of various audiences, from shop-floor operators to executive leadership teams. Through coaching and hands-on implementation, he has supported clients such as SME, Caterpillar, Ford, GM Powertrain, Dana/Spicer Axel, Intuitive Surgical, Nike, Harley-Davidson, Bose, Turner Power Systems, and the U.S. Air Force.

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As a program manager for Ford Powertrain, Perry was instrumental in implementing the Ford Production System at facilities in Lima and Cleveland, Ohio, contributing to their Shingo Prize initiatives. At GM Powertrain, he served as a lean engineer, implementing lean methodologies across 22 North American powertrain plants, focusing on both manufacturing excellence and operational resilience.

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Perry's expertise extends beyond manufacturing into administrative and operational environments, including healthcare, hospitals, and public services. His ability to adapt lean tools to diverse industries underscores his versatility and deep understanding of lean principles.

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Perry is also a recognized thought leader in lean manufacturing. He contributed to Lean Manufacturing: A Plant Floor Guide published by SME, further solidifying his reputation as an authority in the field. His work continues to inspire organizations to embrace lean principles, optimize operations, and achieve long-term success.