Senior Consultant

• Apr 2022 - Present

Process and Product Development Engineering Manager

• Mar 2018 - Oct 2021

Spearheading facility transformation activities allowing for the launch of a new product into the automotive industry. Implementing lean tools and techniques into the transformation in order to optimize performance and develop culture base on continuous improvement and the goal of "ideal state". Developed and implemented 2-bin kanban system linked to company MRP system allowing for automatic BOM updates and label printing. Supporting existing company activities by providing effective and efficient systems that support safety, quality, delivery and cost objectives. Providing engineering support and direction to Supplier Quality Engineering staff based at supplier site ensuring the highest quality products are delivered to our customers.

Quality Assurance Manager

• Mar 2015 - Dec 2017

Enhanced the overall Quality Management System for 2 facilities allowing for three successful, external, ISO audits including a re-certification for the company. Developed and implemented internal auditing program netting 255 updates to processes and documentation in 14 months bringing alignment to system activities and written procedures. Provided critical role in supplier auditing process resulting in supplier corrective actions that prevented catastrophic product failure to customer products.

Kaizen Promotion Officer (KPO)

• Mar 2013 - Mar 2015

Lean Facilitator responsible for development of all processes within the company value stream including waste reduction, problem solving, continuous improvement, Lean financial tracking/reporting and sustainment while improving and supporting all operational and Lean based initiatives. Assisted and facilitated kaizen in 6 different facilities throughout the SSB network contributing to cross-functional networking and Best Practice sharing. Denver: facilitation of 10 events and participation through 6 has resulted in a minimum cost savings of $150K/yr, 30 safety impacts, 25 quality impacts. Janesville: facilitation of 9 kaizen events and participation in 3 resulting in minimum of 78% reduction in process time, 70% improvement in ergonomic rating, 33% reduction in WIP, floor space savings of 400ft^2, 8 safety impacts, 10 quality impacts. Received training through lean global transformation experts Shingijutsu Consulting and attended kaizen training in Japan. Lead inventor of a new process (# US 9,498,069) resulting in $634K/yr savings and revolutionizing the bedding industry.

Executive Operations Manager

• 2008 - 2012

Strategic planning of the Quality/Test Department, as well as implementing LEAN tools and principles into all operational departments. Directives lead to 14% gross margin gain, 160% increase in daily output, and 30% increase in yield rate on GOOGLE assembly line. Initiated standard work tools into all operational activities. Implemented Lean tools and practices into operational activities. Operational direction/management led to direct labor improvements on 63% of all jobs in 2011 netting $77K in additional profits. New management style led to the highest second quarter executive bonus in the history of the company. Managed the re-designed and LEAN implementation into a high volume assembly department resulting in 58% reduction in footprint, 91% decrease in walking distance, 65% reduction in defects and 27% increase in production efficiencies. Implemented new KANBAN system, performance metrics and a visual work place decreasing non-value added labor by 90%.

Lean Manufacturing Engineering Manager

• Apr 2007 - Sep 2008

Managed start up of $1.2 million assembly pilot line: provided all due diligence, ROI reports and procurement for production equipment, as well as, developed layouts, processes and process controls. Implemented on-touch-fasteners and SMED concepts resulting in $136,000.00/year cost savings. Project resulted in 50% reduction is scrap dollars, 83% reduction in WIP, 61% reduction in process time and a 20% increase in production. Developed and implemented LEAN Training and BEST PRACTICES program, lead Kaizen events and distributed training to both management and operations. Created weekly LEAN modules for every department covering 5S, SMED, Jidoka, Poka-Yoke, Takt Time, TPM and more.

Engineering CO-OP

• Jan 2003 - Aug 2003

Received extensive LEAN training through Pella Champions as well as hired LEAN consultants. Held a leadership role in a week long Kaizen event resulting in improved manufacturing processes. Led a TPM project resulting in 30% reductions of scrap, $62K/year in material savings and first ever BEST PRACTICES award for department. Developed process improvements and enhanced machine capabilities in two facilities resulting in $340K/year cost savings. Assisted in design review and brainstorming sessions resulting in new improved window design.