David Fiyalko is a manufacturing and operations professional with more than 25 years of experience driving operational performance, continuous improvement, and organizational effectiveness across manufacturing, automotive, construction, and capital project environments. His background combines hands-on manufacturing leadership with Lean manufacturing, Six Sigma, project management, and business operations, giving him a practical, results-driven approach to solving complex operational challenges.
As Lead Consultant & Project Manager with Distinct Impact Engineering, David leads manufacturing, capital, and operational improvement initiatives for major clients. His consulting experience includes a major capital project for Sub-Zero’s new assembly facility, Lean manufacturing and quality initiatives with Teijin Automotive Technologies, Ford Production System (FPS) strategy and process improvement through Ford’s CAP program, and a plant operations assignment with PSI focused on process development, scheduling, management training, 5S, and plant layout optimization.
Prior to his consulting career, David spent more than 10 years in automotive manufacturing with Ford Motor Company in Chicago, progressing through manufacturing leadership roles focused on safety, quality, delivery, productivity, cost, and continuous improvement. He also brings extensive entrepreneurial and construction experience, having owned and operated Elite Maintenance Inc., negotiated contracts with Fannie Mae, Freddie Mac, and FHA, and served as Vice President of Master Building Inc., where he led business growth, workforce development, and project management initiatives.
David holds Six Sigma Black Belt and Green Belt certifications in manufacturing and brings extensive experience in:
Lean Manufacturing & Continuous Improvement
Six Sigma & Process Improvement
Plant Operations & Operational Stabilization
Capital Project Management & Equipment Procurement
Manufacturing Engineering Collaboration
Production Scheduling & Material Flow
Quality Management
5S & Workplace Organization
Plant Layout & Process Optimization
Workforce & Leadership Development
Operational Performance Improvement
Project Management
