Gerald Melton

Sterling Gabriel, Inc. | Lean Manufacturing Consultant

About Me

Results-driven and dedicated with wide-ranging experience planning and leading operations involving small to medium sized organizations. Track record of devising, evaluating, and implementing continuous improvement to minimize waste and reduce costs while maximizing quality and yield. Establish effective quality control and safety programs, encouraging proactive participation across the plant floor. Excellent communicator; success building cohesive teams focused on production goals, safety, and throughput.

Work Experience

Sterling Gabriel, Inc.
Lean Manufacturing Consultant
April, 2015 - Present
  • Ensured successful manufacturing production runs by assessing risk, setting preventative measures in place, investigating, and troubleshooting equipment and process issues.

  • Coordinated and executed complete re-equipping of manufacturing plant(s) with CNC equipment.

Percepta, Inc.
, Customer Experience Operations Supervisor
August, 2018 - December, 2019
  • Oversaw and assess 12 Customer Experience Specialist, and provide regular performance-related feedback. Strategize and monitor daily activities of customer service operations. Assisting customer service staff with duties where required.

  • Led improvement in Customer Satisfaction for the assigned team by focusing on Customer Follow-Ups, which resulted in a Net Promotor Score improvement of 10% (scale is -100% to 100%).

L3 Harris Corporation
, Materials Manager
April, 2018 - April, 2017
  • Successfully managed production activities so all orders were shipped on time.

  • Investigated and implemented ideas for quality improvement, increased productivity and cost reduction. Immediately addressed all expired product dispositions.

Greene, Tweed & Company
, Value Stream Manager (Production Manager)
April, 2014 - April, 2015
  • Directed, trained, and mentored three exempt Production Supervisors and 70 indirect Production Machinists and Assembly Associates in all aspects of production operations with a singular focus on Safety, Quality, Delivery, Cost, and Continuous Improvement.

  • Led engineering and operations teams through multiple Lean Transformation and Kaizen events to improve operational & personnel efficiency, and cycle times.

  • Completed comprehensive facility safety audits (OSHA Voluntary Protection Program type) and developed an action plan to address gaps.

  • Supply Chain Project: significantly reduced stock-outs in raw materials through a Kanban and GEMBA walks.

Halliburton Corporation
, Senior Production Group Leader
February, 2013 - August, 2014
  • Direct 35 Production Team Members at Electro-Mechanical Directional Lab Module Repair and Maintenance facilities across several shifts and multiple locations supporting customers in the United States, the United Kingdom, Norway, Australia, Thailand, Indonesia, Egypt, Oman, and Argentina.

  • Maintained metrics such as customer satisfaction, on-time delivery, test results, quality index, and safety above plan and best performance at all U.S. manufacturing sites last three years running.

  • Spearheaded efforts to increase facility safety culture using the Dupont Bradley Curve. Guided employees on a journey towards an Independent safety culture (whereby employees took responsibility for themselves, and they believed that safety was personal) versus a Dependent safety culture (whereby employees felt safety was a matter of just following the rules).

Collins Aviation
, Production Manager
August, 2010 - February, 2013
  • Led team of 25 of Aviation Electronic Technicians, and Electronic Assemblers.

  • Managed daily operations to meet production goals for repair and maintenance of components used for aircraft navigation and radio communications, weather radar systems, flight instruments, and engine control systems.

  • Monitored production introduction, equipment efficiency, materials supply constraints, schedules, and staffing levels.

  • Ensure compliance with safety and health requirements including OSHA and EPA regulations.

, Engineering Technician Supervisor
January, 2000 - August, 2010
  • Accelerated emergency response times from three days to less than 12 hours by collaboration with Process Engineering, Manufacturing Engineering, and Wafer Fabrication Management to author escalation guide, recognized by VP of Fabrication Operations for comprehensiveness and ease of use.

  • Knowledgeable of manufacturing laboratory/cleanroom set-up and maintenance. Solid understanding of RF Components (i.e. routers, switches).

  • Achieved and maintained internal customer confidence levels at or above 95% by collaborating with Process Engineers across functions to develop root cause analysis and containment strategies to respond to wafer fabrication process variances.

  • Ensured consistent 90%+ yield of wafer fabrication line via parametric electrical test analysis and statistical process control.

  • Attained ~20% cost avoidance and allowed production planner to reallocate available components in inventory by co-developing and implementing inventory loss reduction strategy to track scrapped, yet saleable parts.


Texas A&M University, Industrial Distribution
2014 - 2016
  • Attended Master of Industrial Distribution at Texas A&M University in College Station, Texas. However, I am one Capstone Project away from graduating.

San Jacinto College, Training, Lean Six Sigma Black Belt Training
2014 - 2014

Guilford College, Bachelor of Science, Business Management with a concentration of Money& Finance.
2002 - 2006

Davidson County Community College, Diploma, Machine Shop Technology
1990 - 1991


  • Accident Prevention
  • Production Management
  • Capacity Planning
  • Production Scheduling
  • Materials Management
  • Safety Documentation
  • Process Improvement
  • Continuous Improvement Initiatives
  • Sales & Pricing Strategies
  • Machinery Acquisition
  • ISO 9000 Compliance
  • Plant Management
  • Forecasting/Budgeting
  • Product Management
  • Customer Experience Management
  • Distribution Management
  • Facility Management
  • Lean/Agile Manufacturing
  • Warehouse Management
  • Inventory Management
  • Purchasing/Procurement



Full professional proficiency