Chuck Cox

Chuck joined Firefly Consulting in 2010. He brings substantial experience, both regionally and internationally, to performance assessment and improvement, as well as product and process design. Over the course of his more than 30-year career, he has worked with clients in diverse industries such as oil and gas, financial services, aerospace, life sciences, utilities, government, optics, automotive, semiconductors, packaging, and computer software and hardware.

With an express interest in process optimization, Chuck has devised and launched operational initiatives that yield millions of dollars in savings for clients, frequently reducing cycle times by more than 70%. He builds rapport quickly while working with staff to increase capabilities and is accomplished at fundamentally improving operations enterprise-wide.

Chuck has delivered quality function deployment workshops in design for the University of California-Berkeley and serves as an adjunct faculty member at Arizona State and San Jose State Universities. He delivered design presentations at several international conferences and currently co-instructs the Master Black Belt professional course for the University of Texas at Arlington.

Publications and Insights

Notable Achievements

  • Designed and executed multi-national deployment for semiconductor supplier with concurrent efforts in Asia, Europe, and North America resulting in $35 million in savings over 3 years.
  • Partnered with a major medical equipment manufacturer to bring a next generation eye surgery product to market 25% faster using Design for Lean Six Sigma.
  • Led an Operational Excellence program for a utility company that resulted in over $22 million in savings and greater than 20% increase in efficiency in the first wave of projects.
  • Developed Design for Lean Six Sigma program focused on the re-design of transactional processes for a leading financial services company.
  • Leader of improved manufacturing process team that reduced change-over time for a stamping line of 7 heavy presses from 2-1/2 days to just under 10 minutes. This created a near immediate 60% reduction in normal stock inventory levels with related cost reductions.


Colorado State University

Purdue University
BS Mechanical Engineering, Economics, Industrial Management

Certified Master Black Belt

Firefly Publications