Tom Grass

Experienced Leader in Pharmaceutical Manufacturing Operations, Plant Strategy Deployment, and Operational Excellence

Greater Boston

About

I am an accomplished Operational Excellence (OpEx) leader and Lean Six Sigma Black Belt with over 20 years of experience in the pharmaceutical, biologics, and life sciences industry. I specialize in designing and leading enterprise-wide programs that streamline operations, improve quality, and foster a culture of continuous improvement. My expertise includes Lean transformation, strategy deployment, change leadership, KPI design, digital enablement, and organizational development within highly regulated GMP environments. I am pursuing freelance/contract work through my consulting business: Grassroots Operational Excellence Consulting, LLC., and am seeking opportunities to partner with pharmaceutical, medical device, or other highly regulated industries to build OpEx maturity through process optimization, cultural transformation, and leadership capability building, delivering measurable value and long-term impact to these organizations. Currently, I am supporting a pharmaceutical device CDMO to improve manufacturing yield, develop tiered management within their manufacturing operations, and provide Lean/Six Sigma coaching and mentoring to Ops staff. This assignment is scheduled to conclude in September 2026. Prior to the launch of Grassroots OpEx, I enjoyed a 20+ year career working in various Manufacturing and Strategic Operations roles for Emergent BioSolutions and Moderna. During my tenure at Emergent BioSolutions, I began as a Manufacturing Technician and advanced through roles of increasing responsibility, gaining expertise in GMP compliance, audit readiness, aseptic technique, and people management. Ultimately, I leveraged this experience into a successful tenure as a Senior Program Manager of Operational Excellence, where I gained understanding of the end-to-end supply chain, and paired that with foundational training in Lean, Six Sigma, and Project Management fundamentals to drive plant transformation. At the corporate level, I helped develop the corporate OpEx program, building a standardized playbook, and governance framework that became the foundation for manufacturing excellence across the network. Following my tenure at Emergent, I joined Moderna, bringing my experience to a novel manufacturing process in a fast-paced biotech environment. Here, I established project governance, improved digital processes in manufacturing, provided Lean training for staff, and supported commercial readiness planning for a new manufacturing facility.

Experience

  • Consultant at Grassroots Operational Excellence LLC
    Apr 2026 - Present · 3 mos

    Independent consultant providing operational excellence (OpEx) maturity advancement across highly regulated manufacturing industries, such as pharmaceutical and medical device. Specializing in designing and scaling value stream management systems, standing up strategy deployment (Hoshin Kanri), providing Lean and Six Sigma training, coaching, and mentoring to employees, and delivering projects with measurable improvements in cost, quality, delivery, and readiness for commercialization.

  • Associate Director, Operational Excellence, INT Strategic Operations (End Aug 2025) at Moderna
    Feb 2024 - Aug 2025 · 1 yr 7 mos

    • Leadership of Operational Excellence strategy and Lean initiatives for Moderna’s personalized medicine division (INT) • Organized and facilitated process improvement workshops to enable phase I, II, III clinical manufacturing of INT • Supported development of labor model for new state-of-the-art large-scale commercial manufacturing plant through process determination, time study execution, and lean project execution • Developed and led governance team for OE projects (intake, endorsement, status tracking) • Deployed lean training to staff

  • Emergent BioSolutions (20 yrs 9 mos)
    • Senior Program Manager, Operational Excellence
      Jan 2020 - Feb 2024 · 4 yrs 2 mos

      • Established the Corporate OE Program including a corporate OE program playbook, comprehensive training curriculum and plant OE maturity assessments • Served as Global Process Owner (GPO) for value stream management, transformation and Gemba Walk standards • Oversaw the OE program in Lansing, MI (2019) and Canton, MA (2020 – 2023) • Devised plant KPIs, plant deployment strategy (Hoshin Kanri), value stream management plans, daily tiered management plans, 6S program, 8 Wastes effort and related problem solving measures • Deployed Kaizen standards (DMAIC, PDCA, A3, 5-Why), Continuous Improvement (CI) Leadership Coaching Program, Gemba Walk standards and Supplier/Customer Agreements (CSA/SLA) • Elevated from the Program Manager role to be a Senior Program Manager in 2020, reporting to the Canton site and serving as a key member of the Canton Site Leadership Team (SLT) • Crafted and launched various highly successful site improvement and corporate OE projects; also carried out plant OE maturity assessments for all company manufacturing plant locations

    • Program Manager, Operational Excellence
      Apr 2019 - Jan 2020 · 10 mos

    • Operational Excellence Specialist
      Jul 2014 - Apr 2019 · 4 yrs 10 mos

      • Developed and administered the site-wide Lean/OE Program, incorporating tiered management processes • Coordinated team chartering and development, serving as an effective mentor and coach • Appointed to be a Trainer on Lean Fundamentals, Systems Thinking and Voice of the Customer concepts • Leveraged problem solving savvy to execute and lead vital plant improvement projects utilizing A3, DMAIC and Quality System processes e.g. Deviation, CAPA and Change Control

  • Research Associate- Inhalation Toxicology at MPI Research
    May 2002 - Mar 2003 · 11 mos