Description
Summary of qualifications: * Extensive manufacturing experience in multiple industries and countries. Experience includes casting, CNC machining, powder coat, e-coat, wood processing, and assembly * Exceptional problem solving skills in team based and individual projects * Lean Certified through University of Michigan. Implement and teach lean manufacturing and problem solving techniques - including Value Stream Analysis, 5S, TPM, Continuous Flow, Standardized Work, Visual Controls, Error Proofing, SMED, Six Sigma, and Shainin * Certified Quality Engineer focused on Statistical Problem Solving, Statistical Process Control, Failure Mode and Effects Analysis, Production Part Approval Process and other AAIG Methods * Use various statistical methods to improve product design / tolerances (DOE, Capability Analysis, etc) * Creator of reporting systems for productivity and quality metrics. Focused on clarity, results, and speed. * Excellent cost analysis skills to demonstrate the bottom line impact of process improvements * Extensive Excel experience and other Office applications Accomplishments: * Documented savings of $2.7 million dollars over 8 years through lean and problem solving projects * Eliminated two-year-old paint chipping problem using Six Sigma and Shainin techniques. Assembly line conditions per 100 reduced by 85%. Rework cost reduced by $215,000 per year * Increased output of Finger Jointing Cell by 36% using OEE methods to identify and implement changes that improved machine cycle time, reduced major downtime, improved quality, and reduced "lost time" * Utilized Six Sigma to reduce paint usage by 17%. Annual savings totaled $99,000 * Lead Lean Six Sigma project with casting supplier. Results included a 40% reduction in floor space, 43% reduction in inventory, 15% reduction in processing time, and a 71% reduction of scrap. Savings exceeded $700,000 * Completed lean project for cosmetic metal forming operation. Project generated $130,000 in savings through improvements in logistics, cell layouts, and process design. * Reduced process lead-time from 2 weeks to 4 days at leather apparel manufacturer. Realized $60,000 in savings. * Ran 5S, work balance, and cell layout Kaizen event for sanding cell. Results reduced floor space by 30% and reduced labor by 1 person * Trained local engineers in Lean Principles in Brazil. Overall project reduced inventory 66% and floor space 25%. Initial Kaizen event lead to $60,000 in annual savings * Created scorecard to identify underperforming suppliers. Metric was applied to corrective / preventive actions, and strategic sourcing decisions. Scorecard could be updated in less than 15 minutes for any of 400 suppliers. * Created Training Modules for lean manufacturing and problem solving. Developed integrated forms and tools for standard work, cost analysis, and quality metrics
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