Tom Dosdall is a Senior Manufacturing Advisor and highly experienced problem solver who has worked across 21 OEM assembly plants in six countries. Over the course of his career, he has built a reputation for tackling complex manufacturing challenges, improving quality, and delivering measurable results in high-pressure production environments.

Tom combines deep technical expertise with a practical, hands-on approach. He is detail-driven, highly analytical, and known for his ability to communicate effectively with teams at every level—from plant floor operators to executive leadership. His experience working across diverse cultures and global organizations allows him to quickly align teams and drive solutions that stick.

Proven Results in Complex Manufacturing Environments

Tom has led and supported high-impact initiatives across the automotive and manufacturing sectors, including:

• Driving multiple warranty investigations with financial impacts ranging from $50,000 to $50 million in savings
• Solving more than two dozen critical issues for an international manufacturer of light and medium commercial vehicles, while coaching internal engineering teams on structured problem solving
• Leading a multinational effort to resolve major paint shop quality and throughput challenges, resulting in a tenfold increase in throughput
• Serving as Lead Supplier Quality Engineer for a major automotive OEM, resolving urgent supplier issues at more than 30 facilities and ensuring long-term corrective action through PFMEA, DFMEA, and DFSS review
• Building and implementing an operational improvement team for a global OEM subsidiary in Sweden, including training, certification development, and team selection
• Training and coaching over 250 engineers worldwide in advanced problem solving methodologies

Earlier in his career, Tom spent nine years at General Motors as a dedicated problem-solving expert before continuing his work through a wide range of consulting engagements.

Deep Expertise in Proven Methodologies

Tom is an expert in statistical problem solving, with more than 20 years of experience applying and coaching structured approaches in real-world manufacturing environments. His background includes extensive use of:

• Lean manufacturing principles
• Six Sigma methodologies
• The Toyota Production System
• Advanced engineering problem-solving frameworks

He is a certified Lean Six Sigma Master Black Belt and a certified Red X Master, reflecting both his technical depth and his ability to lead complex root-cause investigations.

Lightning Problem Solving Methods

After decades of hands-on experience across global manufacturing operations, Tom recognized a gap between theory and execution. While many established methodologies provide powerful tools, they are often applied inconsistently or inefficiently in fast-paced production environments.

To address this, Tom developed Lightning Problem Solving Methods—a proprietary approach that synthesizes the most effective elements of industry-standard methodologies, refined through years of real-world application.

Rather than relying on any single framework, this approach:

• Integrates proven concepts from multiple disciplines
• Streamlines analysis for speed and clarity
• Emphasizes practical implementation and sustainment
• Adapts to the realities of modern manufacturing operations

Lightning Problem Solving Methods is not a replacement for established systems, but an evolution—built from experience, shaped by results, and designed to deliver faster, more reliable outcomes on the plant floor.

Education

• Bachelor of Science in Mechanical Engineering – University of Minnesota
• Certified Lean Six Sigma Master Black Belt
• GM-Certified Red X Master