Engineer Manufacturing
Resume:
Daniel R. Barch
*** ***** *****, **********, ** *5237
*******@***.***
Lean Operations / Training and Practice / Kaizen Leader
Engineering / Project Management / Process & Cost Analysis
SUMMARY:
• Experience in all areas of Production – Supervision, Engineering, Quality, Budgets, Logistics,
Facilities
• Facilitator of Lean Conversion team for plastics facility - 350 employees
• Host 30+ Kaizen events in resulting in multi-million dollar annual savings
• Master Trainer for Lean Manufacturing program in SE Asia – over 400 graduates from 14 week
program
• Project Management: Product Introduction, Facilities, IT, Equipment, Tooling
• Statistical Training and Application for factory managers and operators
• All IE Functions: Costing, MRP, Labor, Process Analysis, Reporting
• Experience in plastic molding, grain processing, textiles/apparel/footwear, electronic assembly,
packaging
EDUCATION:
BACHELOR OF SCIENCE, INDUSTRIAL ENGINEERING, WEST VIRGINIA UNIVERSITY
ASSOCIATE OF APPLIED SCIENCE, PHYSICS, Rochester Institute of Technology
PROFESSIONAL EXPERIENCE:
VFC Asia Ltd.:
Director of Lean Manufacturing, Hong Kong 06/2012 – 08/2013
Implementation of Lean Manufacturing in Asia sourcing factories resulting in verifiable cost savings.
Training of Engineers, Managers, and associates. Evaluation of facilities and organizing solutions.
Nike Inc.: 1999 - 2012
Lean Coach / Industrial Engineer, Beaverton, OR 07/2010 – 06/2012
Training and Development for corporate problem solving sessions. Executed Supply Chain Value
Stream Mapping, Lean Awareness engagements for Liaison office management. Manufacturing focus.
Lean Manufacturing Training Manager, Ho Chi Minh City, Viet Nam 09/2004 – 07/2010
Master Trainer for corporate Training Center located in Viet Nam. Designed and updated 14 week Lean Production
seminar; trained and coached over 400 multi-cultural candidates in labor intensive process improvements. Conducted
multiple on-site Lean application seminars in Viet Nam, China, Indonesia, and Thailand. Initiated TWI Job Instruction
program. Received significant one-on-one Lean Process coaching from multiple Global Lean (TPS) Consultants over six
year assignment.
Industrial Engineer/Lean Coordinator, Beaverton, OR 06/1999 – 09/2004
Process / cost / price analysis for the manufacture of plastic (TPU) cushioning. Lead and assisted with over 30 Kaizen
events with documented savings / improvements. Designed Lean training for factory, warehouse, and office
improvements. Research and Engineering interface for production tooling and product development. Initiated and
maintained system for all routings and BOM. Developed pricing for new products and work center standard costs
resulting in consistent cost control and projections. Assisted in interface and use of beta ERP system. Conducted regular
tours for corporate staff.
Read-Rite, Milpitas, CA 06/1997 – 05/1999
Manufacturing Engineer
Tooling/capacity planning and capital budgeting for offshore production facilities. Responsible for
global head Stack Assembly capacity and overall Philippine facility. Coordinated tooling fabrication and
delivery for overseas manufacturing. Inventory analysis, Technical resource.
American Italian Pasta Company, Kansas City, MO 05/1996 – 03/1997
Operations Controller
Labor and departmental budgeting for plant production; maintained budget tracking and compliance verification. Created
and maintained product cost / pricing standards and routings for 1000+ SKU.
Kellogg Company: 1988 – 1996
Master Scheduler, Omaha NE 11/1995 – 04/1996
Scheduled and coordinated all production and tests for 300 million lb/yr cereal plant; managed
inventories and purchasing of all ingredients and packaging. Designed automated schedule/BOM
interface eliminating daily manual review.
Sr. Industrial Engineer/ Production Supervisor/ Industrial Engineer, San Leandro, CA, 06/1988 – 11/1995
Performed annual Labor and Material budgeting for all operations; ROI and process analysis for new
products, existing projects, and quality exceptions. Maintained all product routing standards. Project
coordination. Delivered productivity / cost seminars for first line supervision and Union staff.
Production Supervisor for 30+ Unionized hourly employees in high speed packaging and grain product
processing. Sanitation, safety, cost control, and crew scheduling issues. Performed job / time studies in
Union environment resulting in crew adjustments and targeted maintenance. Staff facilitator for
committees resulting in 35% water savings during drought. Redesigned labor tracking system and
trained supervision on use. Facilitated daily production meeting. Audio/Visual coordinator. Production
and IT relief.
Trillium Test Systems, San Jose, CA 02/1986 – 11/1987
Manufacturing Engineer
Specified / implemented layout changes and facility upgrades for start up of electro-mechanical assembly & test area.
Evaluated damaged electro-mechanical assemblies. Implemented and documented engineering changes (ECO). Organized
material for assembly as part of 300% production ramp-up.
Stanford Linear Accelerator, Palo Alto, CA 09/1985 – 02/1986
Instrument & Control Engineer
Coordinated the installation and blueprint documentation of control devices and equipment interfaces.
Lee’s Carpets, Rabun Gap, GA 06/1984 – 08/1985
Quality Engineer
Performed statistical defect analysis. Designed computerized Quality reports. Teaching of statistical
methods to multiple facility management and staff.
AWARDS / CERTIFICATIONS:
National Merit Scholar, Rochester Institute of Technology
Dow Chemical National Magnesium Design Contest, First Prize, 1983
Dale Carnegie Course for Effective Communications, 1987
Kellogg San Leandro ‘Most Valuable’ Employee, 1994
Chevron Psychology of Achievement Seminar, 1995
Toyota (Japan) Lean Production Seminar, 2005
Certified TWI Job Instruction Trainer, 2008
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