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Bob Turner

Qualifications:

• Experienced Manufacturing Supervisor with over 22 years of proven leadership skills and a year

as Shift Superintendent with direct reports of production, quality and maintenance employing 45

employees.

• Results driven professional with a proven record for having a detailed eye for reducing costs,

increasing production and quality.

• 23 years of hands-on lean manufacturing experience and 17 years of lean manufacturing training

experience training over 3,000 employees with a cost savings of $10M per year.

• Obtained intensive training in poke-yoke, time studies and 5S in Japan and how to use skills

aggressively to decrease costs. For example, achieved over $5.2M per year in shrinking

changeover time for one line by 84%.

• Won awards for poke-yoke and continuous improvement process and quality deployment projects

at Ford Motor Company.

• Accustomed to motivating union and non -union employees to optimize production and quality.

Proficient in:

Time Studies - Certified in Japan Visual Factory

Quality Deployment Systems, Certified in Japan Kanban, Lean and JIT production

Achieving Quick Changeovers Total Productive Maintenance

Poke-Yoke, Certified in Japan QS-9000 & QS 9000 Quality Standards

8D, 5s and One Piece Flow and Standardizing

Professional Experience:

Corporate Process Auditor 2012 to May 3, 2013

Royal Remanufacturing, South Pittsburg, TN [Consulting]

2nd Largest soda machine remanufacturing, safety and quality process auditor and lean instructor in 4

locations [MO, TN, WV, AZ]

Lean Manufacturing Instructor 2011 to 2012

Volkswagen of America, Chattanooga, TN [Contract Position]

3rd largest automotive manufacturing company in the world. Lectured and instructed all employees on

production systems and quality.

Technical Supervisor 2008 to 2009

Technicolor, Detroit, MI [Seasonal Contract Position] Packaging division of home entertainment

company with up to – 500 employees, packaging assembled movies, DVDs and gaming CDs for release

to the public.

• Supervised eight technicians in highly secure manual and high speed automated packaging lines

to assemble completed newly released movies, DVDs and gaming CDs, supervising eight

technicians / mechanics. Maintained 90-95% uptime of assembly lines through preventive

maintenance and anticipating problems. Worked with suppliers to quickly troubleshoot issues for

JIT deliveries.

Shift Supervisor [Superintendent] 2007 to 2008

Micro Gauge, Brighton, MI. Tier one automotive supplier of yolks and spine tubes with 100 employees

and $30M per year revenues.

• Supervised 45 employees with direct reports including operations, engineering and QC

departments. Conceptualized an innovative significant savings program by turning a one sided

tool into a three sided tool saving over $491,400 per year. Conceptualized and implemented a

cross training program to eliminate calling in dayshift operators to run equipment and paying

overtime, which saved the company $24,960 per year. Maintained optimal productivity during

downtimes by completing ongoing 5s projects and cross training.

Material Supervisor 2005 to 2007

Ace Packaging, Brownstown, MI. Tier one corrugated box supplier of automotive parts for

international and domestic operations with 300+ employees operating 3 shifts 24 hr / 5 days. Supervised

and directed work for 20 employees staging material for assembly operations. Saved company $150k per

year through creating procedure to stage next shift’s production run to eliminate 20 minutes downtime for

material handlers to supply material, which became mandatory for all three shifts. Started 5S effort in

company. Worked on all shifts to garner buy-in and trained supervisors and operators on lean

manufacturing 5S principles.

Contract Supervisor Assignments:

Tower Automotive, Lear Corporation and General Motors. 2005 to 2007

Aerotek Commercial Staffing, Livonia, MI

• Managed 45 welders and devised new ways of working for four men welding team that

consistently achieved 111% production goal from 2800 frames per shift with 20% repair to 3100

frames per shift with zero defects. Supervisor for 80 UAW hourly work force on C-170 Ford seat

assembly line, assembly of engine power train and chassis assemblies [Frames]. Monitored

production efficiencies, minimized downtime, identified issues through scrap investigations and

performed corrective actions. Ensured quality procedures were followed and consistently met

production schedules.

Production Supervisor, Plant Quick Changeover Champion and Trainer 1993 to 2002

Visteon, Sterling Heights, MI. Tier one automotive supplier of drive shafts and rear end components

with 5,000 employees operating three shifts 24/7

Quick Changeover Champion & Trainer

• Created methodical procedure in a Kaizen event using videotaping and time studies to decrease

change-over time by 84% [from 59 min 44 sec to 9 minutes 22 seconds], which saved the

company $1000 per week in downtime. Appointed by plant manager to train other production

lines on procedure as changeover downtime was an issue plant-wide, Trained over 3,000 hourly

and salaried personal in methodology, which significantly decreased changeover times yielding

the company significant cost savings projects.

Production Supervisor 1970 to 1989

Ford Motor Company- Wayne Assembly, Wayne, MI

• Chosen by peers to form Launch Team to go to Japan to participate in two year intensive training

program in lean principals and relocate a stamping line to the Wayne, MI plant. Worked with

manufacturing engineers to identify root causes, implement corrective actions and prove out fix

effectiveness which consistently saved company $80K + per year through 10% head count

reduction. Used detailed time studies which allowed changes to processes by redistributing work

to operators with extra time in assembly process.

Military Experience: United States Marine Corp, Hotel Company 27th Marine Div. Rank: CPL

Honorable Discharge.

Education & Training

Supervisor / Management Institute, Ford Motor Company

High School, United States Marine Corp.

CRC Career Readiness Silver Certificate Chattanooga State Tech CC

Wrote and published a manual on Quick Change over.

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