Zach Wilsterman
Sr. Manufacturing Manager at VirTra- Claim this Profile
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Bio
Credentials
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Lean Six Sigma Green Belt Certification
Six Sigma Global Institute
Experience
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VirTra
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United States
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Defense and Space Manufacturing
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1 - 100 Employee
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Sr. Manufacturing Manager
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Jan 2019 - Present
Directing all areas of the machine shop, I oversee supply chain management, a staff of 22, and process planning for electro-mechanical assembly. I coordinate with the supply chain to vet high-value CONUS and OCONUS manufacturing suppliers, overseeing outsourcing of $2M in machine parts. Leading a team of 7, I've built a high-performing culture, emphasizing continuous improvement, career development, and team collaboration. Key accomplishments:★ Leveraging lean manufacturing techniques including the one-and-done methodology that reduced the number of setup pieces, WIP stops and wait steps, and setup times by as much as 80%★ Expanding domestic and global outsourcing capabilities, including performing financial analysis to recommend shop equipment using WACC and payback ★ Driving strategic enhancements during rapid growth, adding a second shift and doubling production ★ Splitting manufacturing into machining and electromechanical assembly teams to optimize production★ Taking a stagnant project 5 weeks behind schedule and leading the machining team to develop a workable solution that included running 24/7 production, outpacing vendor parts production threefold in <3 weeks ★ Strategizing with R&D engineering by leveraging Design for Manufacturing (DFM) concepts to reinvigorate a lapsed project, leading the team to finish the design and deliver a working prototype in <48 hours★ Implementing Epicor (ERP) company-wide★ Driving material resource planning (MRP) process from conception to launch in <3 weeks to reduce out-of-stock conditions★ Steering a spindle utilization study to elevate shop productivity and maximize shop utilization Show less
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Sr. Mechanical Engineer
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Aug 2016 - Dec 2018
Overseeing the management of a CNC machine shop for a startup, I hired employees, sourced vendors, developed and managed production schedules, and oversaw manufacturing operations. Key contributions:★ Led multiple key initiatives including managing the machine shop’s ERP system, implementing ISO 9001:2015 quality standards, and executing “Lean for High Mix/Low Volume” machining ★ Managed the workflows and daily operations of 4 key employees ★ Mentored the R&D engineering team in design for manufacturing (DFM) principles ★ Recommending equipment to utilize the one-and-done concept that improved workforce capacity ★ Created a state-of-the-shop report highlighting previous accomplishments that led to budgetary approvals★ Developed the machine shop’s first-ever budget ★ Designed and tested a new weapons platform★ Implemented product improvements using DFM and DFA Show less
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Owner
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Nov 1999 - Aug 2016
Leading the operations of a custom design and machine shop I launched, I specialized in measurement fixtures, end-of-arm tooling (EOAT), and test fixtures. Key contributions: ★ Directed a custom engineer group, 12 staff, sales and marketing initiatives, customer quotes, design work, manufacturing, and procurement functions ★ Spearheaded the implementation of Shoptech E2 ERP software ★ Introduced and implemented quality design standards ★ Implemented AS9100C/ISO9001:2008 QMS ★ Coordinated accounting processes including key invoice tracking processes ★ Produced weekly video updates as a tool for communicating project status with customers and highlighting customer testimonials and producing popular holiday mailers with a 40% response rate ★ Recognized as a top CNC Mill Machinist with deep knowledge of programming, setup, and operation of up to 5 axis Show less
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The Tech Group
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Plastics Manufacturing
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100 - 200 Employee
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Project Engineer
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2001 - 2005
I delivered high-quality engineering project management including contract injection mold builds and repairs, collaborating with outside vendors to meet quality standards and stringent deadlines. Key contributions: ★ Introduced, vetted, and qualified production-worthy processes to transfer to production ★ Led data analysis, including writing a VBA script for Excel to manipulate data in seconds instead of 3+ days I delivered high-quality engineering project management including contract injection mold builds and repairs, collaborating with outside vendors to meet quality standards and stringent deadlines. Key contributions: ★ Introduced, vetted, and qualified production-worthy processes to transfer to production ★ Led data analysis, including writing a VBA script for Excel to manipulate data in seconds instead of 3+ days
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Education
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2018 - 2020
Grand Canyon University
Master of Business Administration - MBA, Business/Leadership -
1991 - 1996
Arizona State University
Bachelor of Science - BS, Mechanical Engineering
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