From Chaos to Control — Turning Strategy Into Execution
When operations stall, you don’t need another consultant with a PowerPoint deck.
You need a partner who can walk the floor, rebuild alignment, and show teams exactly how to execute.
Right Brain Left Brain Consulting brings enterprise-level turnaround and continuous improvement expertise—hands-on, fast, and measurable.
⚙️ Transformational Turnarounds
Rebuilding Flow, Profitability, and Confidence
We’ve led full-scale turnarounds across medical device and advanced manufacturing—recovering throughput, culture, and profitability through disciplined engagement and Lean execution.
Every turnaround shared the same DNA: engaged teams, clear accountability, and relentless execution.
Biomet UK (Medical Device Manufacturing, Europe)
A full operational recovery achieved in just over a year.
- Shifted from losses to profitability through Value Stream reorganization and cellular flow.
- Cleared excess WIP, implemented risk-based QMS approvals, and realigned SIOP planning.
- Embedded Six Sigma DMAIIC into CAPA management, cutting closure times and strengthening compliance.
- Improved First Pass Yield from 75% → 98% and reduced lead times from 20 days → 1 day.
- Delivered multi-million-dollar EBITDA recovery and long-term operational stability.
Biomet Microfixation (Jacksonville, FL)
A site once slated for closure became a showcase success in 14 months.
- Reorganized into co-located Value Streams with shared KPIs and team leads.
- Reduced CAPA closure time from >90 days → ~10 days; deviations 20 → 10 days.
- Moved QC into production cells, improving FPY by 30%.
- Achieved a 90% reduction in lead time, $1.5M Lean savings, and $2.4M production value gain—a 3% EBITDA lift with no new equipment or layoffs.
- Invited to present results at TPG’s Continuous Improvement Convention.
🧭 The Secret Sauce: Execution Through Engagement
Strategy Means Nothing Without Tactics
Most firms deliver strategy and KPIs. Few show people how to execute.
We teach teams to turn strategic intent into daily results through a five-month rhythm:
- Month 1 – Assess: Diagnose barriers, waste, and leadership disconnects.
- Month 2 – Align: Build leadership ownership and accountability.
- Month 3 – Reorganize: Create value streams with shared KPIs and co-located teams.
- Month 4 – Strategize: Develop executable plans for each stream.
- Month 5 – Execute: Kaizen → close → repeat.
The result: aligned leadership, empowered teams, and measurable performance gains that stick.
🔍 Transactional Kaizen: Fixing the Hidden Factory
Lean Isn’t Just for the Shop Floor
Up to 80% of manufacturing issues start in support processes—purchasing, scheduling, quality, quoting.
We pioneered a Transactional Kaizen model that brings Lean discipline to these hidden factories.
Through hands-on workshops, we uncover process waste, automate handoffs, and reconnect information flow—saving millions in lost time and freeing the floor to focus on production.
🌍 Global Continuous Improvement Leadership
From Line-Level Kaizens to Enterprise Transformation
Our Operations Excellence model was built inside world-class manufacturing networks—then refined across multiple industries and sites.
As Vice President of Biomet Operating Systems and previously as a Lean Six Sigma Master Black Belt at Johnson & Johnson, Steph led and mentored hundreds of improvement projects, delivering measurable bottom-line impact:
- $42M in savings over three years through enterprise CI deployment across 11 global Biomet sites.
- Established Value Stream/Kaizen operating systems at every site worldwide, embedding continuous improvement into supply chain, quality, finance, and commercial functions.
- At Johnson & Johnson, delivered $11M in savings from HR Kaizens alone, over half a million in bottom line savings while overseeing process improvement across Operations, QA/RA, HR, Maintenance, Facilities and R&D.
- Supported dual-site operations for Second-Generation technology (30 lines in Jacksonville, Florida, 30 in Limerick, Ireland).
These experiences shape how RBLB Consulting partners with PE-backed and founder-led companies today—bringing enterprise-grade transformation discipline without the bureaucracy.
🤖 AI-Enhanced Execution
Amplifying Lean and CI with Next-Generation Tools
The playbook hasn’t changed—but the tools have.
RBLB integrates AI copilots, workflow automation, and predictive analytics into every phase of Operations Excellence.
- AI-assisted Value Stream mapping and process diagnostics for faster root-cause discovery.
- Digital Kaizen dashboards that track cycle times and flag variances in real time.
- Predictive analytics to model throughput and inventory scenarios before physical change.
- Smart document automations that streamline SOPs, CAPAs, and daily management visuals.
These enhancements accelerate transformation while maintaining the rigor and validation required in regulated environments.
Explore how AI can enhance your Lean and CI initiatives