Irvin T. Evans Jr.

**** ******** **.

Home 330-***-**** Twinsburg OH, 44087

cell 570-***-****

abme6d@r.postjobfree.com

PROFILE:

Enthusiastic, High Learning Orientation & Drive for Change, Expertise

in process improvement, Lean Manufacturing Systems, Daily Management

Systems, Process Management, Project Management, Continuous

Improvement, superb leadership skills, product development experience.

Kaizen, 5S and TPM Expert. I am creative and have a heart to help

people be the best they can be.

EXPERIENCE:

Lean Manufacturing Consultant (corporate)

ALCOA EXTRUSIONS & FORGINGS (April 2009- present) Cleveland (Forging)

Operation - Cleveland, OH

. Responsible to develop & deploy Alcoa lean business systems

throughout 7 facilities.

. Two Primary locations: Lafayette, In. responsible for developing

unit II flow-path A3 resulting in 21% productivity improvement 1250

hours/yr saved 4M Lbs./yr. new capacity. Rework and Planned Scrap

A3's developed $2.5M. Pimalco, Az. Cast house startup Kaizen,

Entire facility Leader Standardized Work, Work Design for Extrusion

resulting in record productivity levels for Pimalco. Under-Over

Tolerance and Scrap reduction A3's worth $1.5M. Total improvement

value for 2010 in excess of $3M

. Cleveland, Oh. Turnaround of small aerospace plant, finish area.

30% D.O.T. to 70%. Inventory reduction of $8M, productivity

increased. 28% - 38%, flow time cut by 50%. Leader Standardize Work

all levels of Leadership

. Leader of Development for AFE Supervisory Training: Set up

development and deployment of business unit wide supervisory

development training that is to be deployed in 7 facilities and

world wide in 2011. Built core team, partnered with training

structural designers from DDI and Kent State. Developed and

deployed internal sustainability and marketing strategy. Training

program thus far has been met with rave reviews.

TPM Coordinator (corporate)

ALCOA INVESTMENT CASTING AND FORGED PRODUCTS (2007 - April 2009)

Cleveland (Forging) Operation - Cleveland, OH

. Responsible to develop & deploy TPM system for 5 facilities and

successfully attain various TPM levels on over 50 pieces of

equipment and 5S in all areas of each facility

. Within 3 months of hire I had all facilities active on TPM and 5S

(Received Exceptional contributor on year end review)

. Developed roles and Spa's by facility to champion the program in

their facility

. Trained all leaders and hourly employees on TPM overview and level

achievement

. After 3 months in the role I was asked to take a temporary

management role in the Small Aero Space plant within Cleveland.

During the 10 months in the role productivity and throughput were

increased by 16% and the backlog was reduced by 90%. On the largest

press the production value add improved by $2MM annually. I was

awarded the "you make a difference" award for the development of

Leader Standardized Work by the business unit president Mr. Raymond

Mitchell. The L.S.W. was accepted as best practice and is currently

being disseminated throughout other Alcoa facilities. During the 10

month assignment I also was asked to manage the chip and trim

department and drove a $1.3MM annual improvement due to the

elimination of outsource chip via increased daily throughput from

60 hours/day to 130. I also spent time in the final department

where I developed tools to be able to set daily forecast by piece

for zyglo and repair and redesigned the repair department to

improve quality to zyglo thereby increasing zyglo thru put from 20

hours/day to 38.

. After 10 months I handed the manufacturing department off to a new

superintendent and then was asked to move into the Large Aerospace

plant

. I started in September of 2008 in a consulting role for Large Aero.

Within 3 months we managed to improve throughput and productivity

to record levels. The large 50K press went down and we were able to

produce its volume and the volume of the smaller 35K press on the

35K press alone to within 5% of the 2008 average of both presses

combined. This led to the reduction of 10 people. We rolled out the

Leader Standardized Work as I had in Small Aero., built daily

management into the work flow, added FIFO slides and scheduling.

Manufacturing and Engineering Manager

ALCOA INVESTMENT CASTING AND FORGED PRODUCTS (2006 - 2007) Bethlehem

Operation - Bethlehem, PA

. Leading manufacturing operations with 150 people (6 direct reports)

. Responsible for turnaround of manufacturing portion of casting

business $12MM annual revenue

. Led NDT department out of disclosure from March - July 2006

. Awarded Manufacturing and Engineering manager in July resulting in

12 month improvement of:

o TRR (Total recordable injury rate) improved 74%, from 2.3 to

0.6 from top 5 worst in Alcoa to top 5 best.

o Net Margin improved $10.2MM or 66%, from -$15.5MM to -$5.3MM

o Scrap Rate improved 48%, from 21% of revenue to 11% of

revenue

o Labor Productivity (Conversion Revenue per Labor Hour -

CRPLH) improved 46% from $26 to $38

o Inventory DOH improved 26% from 65 days to 45 days

. Net result was this plant was staged to be closed and thru the

efforts of the team Alcoa was able to sell the plant and 130 jobs

saved.

. Our team was also nominated for an Alcoa Impact Award for

excellence due to the success of the endeavor.

DIE MANUFACTURING BUSINESS MANAGER

ALCOA ENGINEERED PRODUCTS (2003 to 2006) Cressona Operation

- Cressona, PA

. Leading manufacturing operations with 40 people (3 direct reports)

. Responsible for profitable growth of internal tool and Die Mfg.

$5MM annual budget

. Led Improvement of Department cost reduction of over $3MM annually

. Led Improvement of Inventory reduction of $500k

. Led Improvement of Quality PPM from over 20000 PPM to less than

3000

. Led improvement of average On-Time performance to 99% on-time to

customer last 2 years

. Member of Operation Lead Team that reduced Manufacturing Cost by 9%

or $10MM/yr rate over 3 years

. Led through Conversion from legacy computer system to Oracle EBS -

awarded "Alcoa You Make a Difference Award" for leadership through

this conversion

. Trained, Coached and Expect use of Standard Work Instructions,

Problem Solving, and Experimentation (A3) techniques

. Built and trained team in the use of Excel-based Planning Tools to

improve planning, forecasting and inventory management as well as

developed custom Unigraphics automation to reduce process time from

15 hrs. /Job to less than 3. Also developed various data bases to

track all daily data and production information, due to Oracle

ineffectiveness'

. Implemented Daily Management System in department and championed

the use throughout the Operation

. Championed Practical Problem Solving and Experimentation throughout

the Operation

. Sole developer for Die Technology

. Developed new products to improve pounds extruded per hour by 30%

. Developed new technology to position Alcoa to thrive in high aspect

ratio heat sink market

. Highlights for this position: Shop was to close in 2002 we turned

it around in one year to convince Alcoa it could add value! The

shop was a cost center since its beginning, 2005 returned 4% ROC.

$250K NOPAT

. Led Safety efforts to reduce TRR rate by 30% in 2 years.

FABRICATIONS AND DIE MANUFACTURING MANAGER

ALCOA ENGINEERED PRODUCTS (2004 TO 2006) Cressona Operation

- Cressona, PA

. Leading two manufacturing operations with 130 people (14 direct

reports)

. Responsible for profitable growth of internal Aluminum Fabricating

business and tool and Die Mfg. business $15MM annual budget

. Led Improvement of Department cost reduction of over $2MM annually

. Led Improvement of Inventory reduction of $400k + $800K on hand lbs

to fewer than 400K.

. Led Improvement of Quality PPM from over 10000 PPM to less than

2000. CPM to .43 2005 fewer complaints than previous 4 years.

. 2005 was most profitable year for the business in its history.

Average NOPAT the last 4 years was under $200k. 2005 resulted in

$500K with a 12% ROC.

. Successfully implemented 1st level daily management by end of 2004

and started with Australian model daily Mgmt. boards in Jan. 2006.

. Lead Safety efforts to reduce TRR rate by 52% in two years. 2003

TTR was 6.5 2005 3.1

. Successfully restructured two businesses to reduce head count from

181 to 139 total savings of over $2MM. Also resulted in a 72%

productivity improvement for the Fabrications business. Average

production lbs. were 25MM to 46MM by 2005, $5M in additional

revenues. Opened capacity to 48MM Lbs. + annually.

. Lock Tag Try SPA for entire operation

DIE MANUFACTURING TECHNICAL MANAGER

ALCOA ENGINEERED PRODUCTS (2001 TO 2003) Cressona Operation

- Cressona, PA

. Lead technical team of 14

. Primary focus was to develop product designs and systems to produce

those designs with minimal people interaction/knowledge (black box)

. In three years I developed systems that reduced administrative

labor from 24 to 9. Developed automated solution for all CAD and

CAM operations within the group

. I acted as the sales and marketing manager for the die business and

brought in 13 new customers. Average monthly volumes went from 400

total jobs/ month to over 900. Revenues went from $2.5MM to over

$8M

. Design and programming time went from 12 hrs to less than 3.

. Some of the products that I developed improved production on the

extrusion press by over 30%. For a business that was at the

forefront of productivity within the Alcoa extrusion businesses.

Prior to the technology that I developed Alcoa could not compete in

the High Aspect Ratio Heat Sink market. Alcoa's technology would

only allow 5:1 or lower I successfully developed up to 21:1 which

gave us the ability to practically own that market.

. I worked with all outside vendors to insure top quality supplies

and reduced cost for expendable tooling by over 40%. Annual cost

was in excess of $600k, currently it is under $350K annually.

TOOL AND DIE TECHNICIAN

ALUMAX (1999 to 2001) Cressona

Operation - Cressona, PA

. Responsible for die design improvements

. Develop and track new designs

. Statistical data reporting for all design performance

. Train all design technicians on design concepts

. Customer technical visits for problem solving/root cause and

solutions for improvement

. Project management

QUALITY SYSTEMS METROLOGIST

ALUMAX (1998 to 1999)

Cressona Operation - Cressona, PA

. Responsible for the operation quality system measuring and test

equipment program

. Developed current measuring and test equipment calibration system

. ISO internal auditor

. Developed many of the quality ISO procedures for the entire plant

. Trained all users on measuring and test equipment, calibrated all

of that equipment

TOOL AND DIE INVENTORY CONTROLLER

ALUMAX (1996 to 1998) Cressona

Operation - Cressona, PA

. Responsible for all tooling and die inventories

. Responsible to insure all tooling is operational

. Worked with repair and manufacturing departments to insure tooling

was ready for the press line.

EXTRUSION SHOP FLOOR

CRESSONA ALUMINUM & ALUMAX (1983 to 1996) Cressona Operation

- Cressona, PA

. Worked various production and quality inspection positions within

the extrusion department.

EDUCATION:

Practical Problem Solving Center of Excellence (Alcoa), Dover NJ

2007

DDI Leadership Training

2006

Harvard Business Simulation Training

2001

2 Year Management program PENN STATE

2000

Gage calibration Systems, Mitutoyo

2000

Kaizen Facilitation, Cressona Operation, Cressona, PA

2000

Alcoa Practical Problem Solving Train-the-Trainer training

1998 Cressona Operation, Cressona, PA

Various PC training while at Alcoa,

Excel Access, Word, Oracle, and Unigraphics Albright University.

Reading PA. 1997-2003

Graduate of Pottsville area High School

1981

EHS, Ergonomics, TPM, Leadership, Quality, Manufacturing training and

experience throughout 27 years at 3 different Alcoa Locations

Successfully completed Alcoa Management Assessment, Johnson City, TN.

Additional materials and data are available upon request. A3's,

problem solving examples, reports, performance review, etc.

References: Available Upon Request

Contact this candidate