Experience

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  Self-Employed

  • Lean Professional

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  self

  • Lean Professional

    • Oct 2009 - Present

    Self employed

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  General Motors

  • Global indirect IE

    • Jan 2009 - Sep 2009

    Global lead IE working on indirect improvements

  • Lean Manager/Consultant

    • Jan 2005 - Dec 2008

    My duties include Lean Manufacturing training/workshops at General Motors facilities and suppliers. This comprised developing Specific training packages, Implementation, "Train the Trainer" and Coaching. Completed Continuous Improvement/Kaizen workshops to improve Value added and reduce Walk/Waiting time, treating the employee as the customer.Worked in Existing and Greenfield facilities in USA, Canada and Mexico from Concept to full Production.Trained over 400 employees in small Team Building workshops, Operational Readiness, Standardized Work, Problem Solving and Job Instruction Training (JIT).Lead Lean Coach, managing a team of (10) coaches, during the Implementation of our Global Manufacturing System at a Greenfield site in Michigan following the proven concepts of our Antwerp, Belgium facility.

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  General Motors Asia Pacific Group

  • Plant Launch Manager

    • 2003 - 2004

    2003 to 2004My duties included the transfer of a Body shop from South Korea, conversion of the Paint shop and General Assembly departments for the production of a new small car. This included kit build-up to complete local assembly and sourcing. As part of the knowledge transfer process, managed/coordinated groups of Engineers and production employees on vision/learning trips to our South Korean facilities to learn the assembly process.The product was launched, meeting Production and Quality targets, within one week of scheduled Start of Production using a "Batch and Hold" method of quantifying quality. Coordinated our Lean manufacturing process roll out, Plant Operations, day to day issues and Quality issues with the Korean suppliers and local operations.Developed a Master dot/Implementation plan to meet the local sourcing requirements with our Supplier Quality department.I had (5) direct reports and approximately (400) indirect Chinese nationals.

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  General Motors North America

  • Production Manager XLR

    • 2002 - 2003

    2002 to 2003I executed the complete initial Production process and Launch of the Cadillac XLR sports car. This included working with the Launch/Engineering teams to address first time quality, introduced our GM Production Process and solving significant Fit/Finish issues using Red X techniquesDeveloped a Plant wide Workplace Organization standard and implemented it in the XLR area using 5S techniques.Initiated development of Job Element sheets (JES) as the precursor of Standardized work. Balanced workload between operations and managed the repair/retrofit process on the weekends.I had (3) direct reports, (60) Production employees and interfaced with Quality, Reliability and Engineering departments.

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  General Motors Europe

  • Engineering and Lean Materials Manager

    • Jan 2000 - Jan 2002

    Developed and launched a Tier One Logistics Center, while introducing Lean principles to the facility. Directed our Assembly Engineering department during the launch of a new product. My duties also included interfacing with our German Technical Center for Prototype builds and Line processing.Renovated an adjacent facility and hired the Tier one to manage direct and indirect materials including over (100) Sub-assembly and Sequenced modules.Implemented Plant metrics/score card system for General Assembly. Increased value added work content 20% through line-rebalancing efforts.Directed the implementation of Lean Manufacturing/GMS on the plant floor for Materials and Assembly departments.As a Lean consultant, helped our Ellesmere Port Logistics Center in England come up to production. I had to understand and remove the bottlenecks and implement appropriate solutions including visualization, Andon, Kanban card system and route management.I had (5) direct reports and over (100) indirect Portuguese nationals in the Logistics center.

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  Opel Poland

  • ME and Launch manager

    • 1998 - 2000

    charged with the planning, execution and conversion of the Paint and Assembly departments for a new car and increase the line rate from 12 to 30 cars per hour with Polish nationals. The primary focus was to introduce Lean Manufacturing/Principles to new hires through a progression of prototype builds in our Joint Venture Japanese Technical center in Hamamatsu Japan. Using off-line training, then train the entire Assembly department in how to build the car at production rate with excellent quality. While in Japan, developed a core team of (20) Polish national's eventually building 100% prototype cars and developing 100% Job Element Sheets (JES).Managed turnkey relationships on Layouts/approvals/installation of new process equipment.Introduced a Workstation Certification and Diagnosis process that became the basis for the current GMS Operational Readiness process.Implemented the removal of (48) modules to the new Logistics center without loss of production or quality.Working on implementing various lean manufacturing tools on plant floor with sustainment as the goal, using the "train the trainer" approach.

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  General Motors MidLux Group

  • Engineering Group Manager/Assembly Launch manager

    • Jan 1994 - Jan 1998

    Responsible for the Staged conversion of the Paint and Assembly shops while maintaining current production resulting in becoming the Assembly Shop Launch manager for the C5 Corvette.Project/Resource manager for the modernization of the Paint shop including new Prime, Main, Repair and fascia booth /ovens, new inspect/finesse, moist sand decks, Automatic Storage and Retrieval System (AS/RS) using (100) GM skilled trades.Lead engineer responsible for the design and installation of all conveyors from Body and Paint departments throughout Assembly. This included installation of all process tooling, development of System layouts, ergonomic and operator assist devices.Assembly Launch manager responsible for the introduction of the 1997 and 1998 C5 Corvette. Generated and updated Master schedules, including manufacturing Engineering tool validation and early operation set-up. Worked maintenance breakdowns, day to day problem resolution and throughput initiative projects. Worked with all levels of the plant from the Plant manager to the team member on the plant floor. The 1997 Launch was awarded GM's Chairman's honors for being very well executed.Lead Body and Assembly shop Throughput teams (TIP) resulting in meeting unscheduled overtime goals.

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  Industrial Engineering Services

  • Group Manager

    • 1991 - 1993

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  Design Systems/Engineering Services Group

  • Manufacturing Consultant

    • Jan 1987 - Oct 1989

    Developed and directed teams of Engineers providing Bid package development, Field support, simulation studies, Benchmarking activities and Brownfield/Greenfield planning for various international clients. Benchmarked and developed the initial design for a European Auto company's first factory in the USA.Managed up to (12) direct engineers.Developed the "Master plan" for the re-arrangement of the Engine facilities for a major Off Highway equipment Manufacturer.Designed and Simulated Automatic Guided vehicles Systems (AGVs), Automatic Storage and Retrieval systems (AS/RS) and multiple conveyor systems for Major US Auto companies.

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  Oldsmobile Division and Buick/Oldsmobile/Cadillac (B.O.C) Group

  • Staff

    • Jan 1977 - Jan 1986

    Progressed through Various plant and staff positions with increasing responsibility. Purchased and installed Engine and suspension component machinery, Designed and instaled Major Chassis sub-Assembly systems and provided field support to B.O.C. group plants.Participated in a treasury department study to purchase an AGV company.A member of ANSI B56.5 National standard development team on AGV's.Developed GM's first corporate conveyor standard CS-1

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  General Motors Institute

  • Staff Enginner

    • Jan 1969 - Jan 1976

    Served a (4) year Engineering Apprenticeship covering all main Plant departments, including Machining, Assembly, Welding, Inspection and Engineering.(2) Year Fellowship at Terex

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  General Motors Scotland

  • Engineer

    • 1969 - 1976

    Overseas Operations Fellowship and (4) year apprenticeship