Uncle Bob: Strategic’s Master of Lean Management Retires

As Managing Director of a global factory, Norman Cheng had heard whispers of the concept called ‘Lean Management’ in the early days of 2006. At that time, China was still in the midst of plentiful labor, stable currency exchange and stable inflation, and it was then that Cheng was introduced to Bob Fesler, a Lean Six Sigma Black Belt. 

Over the course of two weeks, Fesler, who Cheng would eventually refer to as ‘Uncle Bob’ introduced the Strategic Sports team to Toyota's concept of continuous improvement.  

After these workshops, Cheng reviewed what they had learned with Strategic’s leadership. Several members of the team shrugged, saying it was nice to have time away from the office but they were not convinced of the value of what Fesler was teaching.

Fast forward five years, the Chinese RMB dramatically appreciated against the US dollar, and when Cheng was looking to hire 300 new people, only 30 showed up to be interviewed. Material costs were fluctuating wildly. Cheng again gathered leadership to discuss how Strategic Sports should face this new future. 

In the back of Cheng’s mind was an American, who five years earlier had predicted the market would require more competitive costing, lower MOQ’s and shorter lead times. After searching his memory and scanning LinkedIn, Cheng tracked down Bob Fesler, who had by then returned to the US and was no longer a Lean Coach.  Cheng coaxed him back to China to mentor and coach Strategic Sports at this key moment. 

Walking through the warehouse, Fesler pointed to some parts stored in a bin on a shelf.

“What is this?” Fesler asked. The warehouse manager explained part.

“And the quantity?” Fesler continued. The manager responded.

”And the date this was placed in the warehouse?” Fesler asked.

Again the manager, now sweating, pointed to a card with this information. And then Bob pointed at another bin in front with a later date, asking, “So how will you ensure the part that came earlier will be used first?” An important lesson in FIFO, or First-In, First-Out warehouse management!

This past week, Fesler returned to China for the first time since COVID. “We were delighted to meet face-to-face again and like eager students, we showed him our latest streamlined production processes,” Cheng said. Fesler reviewed the recent work and offered encouragement and also pointed out areas of improvement. Some of the younger engineers looked devastated.

“Hey,” Fesler said, “This process is called continuous improvement for a reason!”

After several productive days, Fesler pulled Cheng aside one night at dinner and announced that he will not be returning to China, as he wishes to truly retire. 

“Bob’s insight and expertise has been invaluable these many years,” Cheng said. “He has helped us far beyond increasing our efficiency and improving our processes. Bob has helped our entire team grow and learn to think differently in everything we do, and that is a gift beyond measure,” Cheng said. 

Thank you, Uncle Bob. The team at Strategic appreciates all you have taught us and we look forward to staying connected online.