wi8ali@r.postjobfree.com

Richard Herman

**** ***** **. •Camarillo, CA ****2 • Phone: 805-***-**** • e-mail: wi8ali@r.postjobfree.com

PROFESSIONAL EXPERIENCE

Proven, highly capable professional with 8 years of field experience throughout USA and Mexico in operations management • Trained under the Toyota Production System philosophy, working with management in designing and executing operations improvement, utilizing concepts of the Toyota Production System • Led and executed over 100 kaizen activities throughout the automotive, biotech, mattress and lighting industries.

Life Technologies (Invitrogen) Camarillo, Ca April 2008 – Present

Functional Excellence Manager – Corporate

High-mix, low volume products both extracellular proteins and intracellular proteins and their function in understanding the disease process

Utilizing Toyota Production System ideologies to help develop upper and middle management for operational improvement through the implementation of a Kaizen Promotion office. (Approx, 150-200 employees 20 million – 30 million revenue size)

Through creation of standardized work condition led to a reduction of 1 shift and a manpower reduction from 16 people to 8 people in packaging. Led Management in the plan and execution of factory transformation, utilizing kaizen activities, resulting in (for example):

Implemented address system based on usage and product family, standardizing Inventory Control process reducing cycle time 20%

$600,000 overall improvement including Cycle Time and labor reduction (2008)

Developed and delivered Toyota production system (Lean production) overview, standardized work and kaizen activity “day one training” for development of factory Kaizen Promotion office and supervisors at the manufacturing facility

Standardizing process per department through an upstream perspective, introduction of GEMBA (plant tours) giving upper and middle management a shop floor focus

Cooper Industries (RSA Lighting) Los Angeles, CA April 2007 – April 2008

Continuous Improvement Manager

Medium-mix, medium volume recessed lighting assembly operations

Responsible for the management of operational improvement (Approx, 150 – 200 employees)

Labor Reduction ($300,000), improved site through numerous kaizen activities and value stream mapping activities on the shop floor with teams ranging from 8-16 to achieve operational goals

Led the strategic planning & review sessions for operations improvement with results of reducing manufacturing space by 2,532 sq. ft. or 18% of total facility, cell conversion to U-Shape Cell 40% plant overall and inventory reduction by 20%

Reducing direct manpower by 15%, savings over $250,000 yearly on an ongoing basis, identifying and solving bottlenecks dropping in defects from 15% to under 3% in final assembly that caused 2 – 3 hours of daily overtime

Sealy Mattress Company Los Angeles, CA January 2005 – April 2007

Continuous Improvement Coordinator (Northern & Southern California, Oregon)

Medium-mix, high volume bedding operations

Responsible for the management of operational improvement for two factories and supported 2 additional sites (Approx, 200 – 300 employees per plant)

Lead numerous kaizen activities and value stream mapping activities with the following results:

Responsible for continually driving down plant production costs through the implementation of TPS, by increasing labor productivity by 21%, decreasing labor costs per piece by 24%, quality costs by 63%, scrap by 34%, product refusals by 60% and benchmarking KPI’s - over 1 million dollars saved during 2007.

Key team member involved with turning around Los Angeles Plant from 17th to 1st in the nation winning the Lean award for 2007

Pivotal in establishing yearly, lean manufacturing strategies by encompassing semi-annual planning sessions and value streaming to align with budget constraints, led the strategic planning & review sessions for operations improvement creating liaisons between other regions in order to establish “Best Practice”

Analyzing the Bill of Materials cost from suppliers and identifying which suppliers need kaizen assistance so that profit targets can be meet

Worked closely with TBM consulting as the point of contact for the Los Angeles site.

The Noonan Group, Inc Monterrey City, Mexico May 2002 – January 2005

Operations Manager (Northern & Southern Mexico)

Management Consulting Services

The Noonan Group, Inc management consulting affiliate primary provider of quality consulting and process validation services to DaimlerChrylser, Ford Motor Co. and General Motors.

Responsible for coaching suppliers to implement and sustain operational excellence through utilization of Supplier Quality Engineering Consulting, Supply Base Development-Management, line standardizations, process engineering, Quality engineering, Liaisons Services & training. APQP such as Control Plans, Process flows, Measurement Systems Analysis, Reliability & Maintainability, statistical methods based out of a Web based software: HYPERLINK "http://www.evalidate.com" www.evalidate.com. Clients come from automotive suppliers and from non-automotive manufacturing and service companies.

Set up, daily review of software/projects, business development in Mexico for suppliers in the automotive industry, supervising regional manager’s throughout Northern and Southern Mexico, on-site field support when necessary, managing projects with profits of $300,000 US per month.

Created partnerships with OEM’s such as Ford Motor Co. (Hermosillo), Daimler Chrysler (Saltillo), Toyota (Tijuana), Lear Corporation (Saltillo), JCI (Johnson Control)

Implementation of programs for employee recruitment, development and retention. Development of efficient corporate policies that where cost effective and capable of adapting to change. 


RELEVENT ADDITIONAL SKILLS & INFORMATION

Extensive work in: • Mexico • U.S.A.

Conversational Spanish language ability • technical Spanish

Extensive process-level work at different types of manufacturing facilities in Mexico and the U.S.A

Worked with all levels of management and employees as the primary consultant for TPS, leading numerous kaizen activities in many different types of processes

Designed a standardized work workshop for both the classroom and shop floor

Conducted training individually or as a part of a team in TPS, standardized work, M & I Flow (value stream mapping), and problem solving for numerous companies.

Operational Analysis

Worked with Top Management (V.P. & Plant Managers) in analyzing shop floor production method and presenting kaizen plans to overcome

Trained Top Management, Kaizen Promotion Office, kaizen team personnel and team leaders in relevant Toyota Production System (Lean Production) concepts.

Focused on supply chain issues such as:

Analyzing supplier factories, identifying kaizen opportunities and creating kaizen plans to overcome

Six Sigma Green Belt Certified

EDUCATION & HONORS

Bachelors of Science in Industrial and Systems Engineering

Monterrey Institute of Technology Monterrey, Mexico (2000)

Emphasis: Manufacturing Excellence (Lean Manufacturing)

Accredited by the Southern Association of Colleges and Schools (SACS)

Completed Trainings Available

Toyota Production System (Lean Production) Overview - With Simulation

5S (With video)

Motion Kaizen (With team based activity)

Leader Standardized Work (With simple simulation)

M & I Flow (Value Stream Mapping)

A3 Training

MDI (Managing for Daily Improvements)

Relevant Organizations I have worked with

TBM Consulting Group – Lean Enterprise Advancement Program

CELERANT Consulting Group

LECTURES & PRESENTATIONS

Guest Lecture, APICS Association for Operations Excellence Ventura County Chapter USA (2009)

Topic: Toyota Production System Striving for True North through Human Development

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