Summary

I am a seasoned Lean Leader with a long history of implementing Lean and leading companies to World Class status. I use fact based Lean, Kaizen and Six Sigma projects to achieve success saving millions of dollars in increased productivity, increased quality, reduced costs and reduced inventory. I have mentored dozens of Lean practitioners enabling them to develop integrated Lean Systems and sustained cultural changes. I understand change, the fear it creates and how to resolve it. I have many years of experience developing Corporate Strategic Goals incorporating the use of Lean.

Skill Sets

I am a Lean Master with extensive hands on experience in mixed model line design, plant layout, Kanban, line balancing, Value Stream Mapping, SMED, Demand Management, team facilitation, flexible employees, implementation and metrics setting. I am comfortable training and working with hourly employees to Corporate Boards and mentoring them to expect and achieve success. I use Six Sigma tools to measure and control processes, define and eliminate quality issues and to show project progress. I have designed and implemented advanced Lean based software for several different companies to use for their Lean implementation and Demand Planning requirements. I map business processes and systems, assessing their maturity, using the APQC Process Classification Framework.

Professional Experience

Lean Management Consulting 2008 – Present
I am working for the Confidential, a US Department of Energy National Lab operated by Confidential, to establish process mapping, process improvement, gap analysis and change management in order to provide a basis for a Malcom Baldrige National Quality Award application. I am also conducting classes in Lean Fundamentals for the Lab and University to develop a broad understanding of Lean.

I have been working with managers, in other facilities, to develop metrics that define their strategic goals to be realized by Lean implementation and offering training and direction to achieve their goals. 

Confidential 2006 - 2008 
Division Kaizen/Quality Manager 2006 – 2008
I implemented projects in manufacturing while training more than 100 employees in Lean tools for cross functional teams. Our annual savings exceeded $930,000 while improving material flow and reducing throughput time. I implemented 5S programs leading to measurable improved productivity and safety. I developed an Engineering Change Control program to provide control for the impact of the 100’s of ECN’s created annually. I led the Business Management System and ISO certification for the Division and was the ISO Management Quality Representative. I defined the Quality Systems for the Global Sourcing program including First Article Inspection. I introduced Six Sigma tools in the Quality Group resulting in greater awareness of the cause of defects. 

Confidential. 2004 – 2006 (Now known as DemandPoint)
Director of Process Improvement 
I defined and implemented the required steps for clients to improve or initialize their Lean programs as an advisor or as a Team Leader. I directed projects on individual lines and entire factories. I conducted Lean assessments for potential customers developing strategies and implementation plans to achieve their corporate goals. I defined the data sets used to support our efforts and trained users and clients in Lean practices and methodologies. I developed several of the functions used in the software suite we offered that enhance Lean development and implementation.

Consulting Private Practice 2001 - 2004 
I delivered training and support for Lean Flow and Reengineering. I developed and taught a DMAIC based Lean Flow course, in conjunction with Six Sigma US, in both public and private classes while working as a Lean consultant in manufacturing and transactional based environments. I implemented Lean Flow for various companies and set their process improvement directions.

Confidential 1977 - 2001
Corporate Process Improvement Leader – Piscataway, NJ, 1997 – 2001
I led managers and plant teams in two dozen countries in reduction of inventories, cycle times, and costs while dramatically improving Customer Order on time fill rates. I developed and implemented a Finished Goods Right Sizing program for the European Sector that improved Customer Service from 56% to 99.9% within a year while reducing total inventory by more than $1MM. I reduced costs and improved performance to certified World Class standards for several facilities including two that held a zero change to Standard Costs for three years in a 35%+ inflation economy. I developed and delivered training in all aspects of Lean Flow and Demand Flow Technology for all levels of the company in all 4 Divisions. I developed procedures and training for High End Kanban, machine cells, finished goods right sizing and mixed model line design. I developed a formal program for assessing facilities status in implementing Lean Flow to determine their ability to use Demand Based Planning. I implemented flexible employee practices around the globe, adjusting for cultural differences, in all sectors, increasing productivity and capacity. I received a Lean Master certification in Lean Flow and Demand Flow and mentored several other Masters and Lean Black Belts to certification. I was a on the team that developed the $20MM in-house software used for all aspects of Lean, Standard Cost and Demand Planning within the company. 

Demand Flow Technology Systems Coordinator - Confidential, 1993 - 1997
I developed and implemented Lean systems for manning requirements and capacity improvements. I designed and implemented a cutting edge RF based Warehouse Management System in the Americas saving $2MM annually. This system improved load make up and product allocation to achieve targeted on-time deliveries by defining Plant shipping requirements to reduce Distribution Center handling. I provided technical assistance for the design of the American Software Inc. Flow Manufacturing System. I co-developed and implemented the Demand Planning and Standard Cost systems in the Americas Plumbing sector based on Lean Principles.

Demand Flow Technology Training Manager - Confidential, 1990 – 1993
I was the Team Leader on the first Lean team for the company. Our substantial successes led the company to adopt a Lean culture for the entire corporation in all sectors, 110 sites. I implemented changes to line designs improving one piece flow and reducing cycle times in plants that reduced costs in the group by $3.5MM annually. I developed and delivered training in mixed model line design, flexible employees, quality procedures and Kanban in five countries, occasionally using simultaneous translation.

Operations Manager - Trenton, NJ, 1986 – 1990
I was responsible for all processing departments in a 24/7 300 employee plant covering production, scheduling, budget, quality, safety, human resources, maintenance, engineering and strategic planning achieving very high on time deliveries. I developed quality plans, new product processing plans, new products and annual budgets while implementing cost reductions and implementing production improvements. I mentored supervisors and technical personnel in leadership skills and improved first pass yields eliminating scrap and rework using SPC and establishing defined work steps.

Plant Industrial Engineer – Plainfield, CT, 1981 – 1986
I had a Classical Industrial Engineering position with responsibilities for Methods, Standards, Negotiations, Standard Cost, Continuous Improvements and Capital Equipment justification. I also led new process and technology implementation, cost variance investigations, supervisor training and I trained Industrial Engineers in classical IE work for the other Plumbing Sector plants. 

Senior Industrial Engineer -1978 – 1981
Industrial Engineer -1977 – 1978

Education

AS General Sciences – Confidential College 
AAS Chemical Engineering – Confidential College