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Lean Sensei

Location:
Madison, Alabama, United States
Salary:
Negotiable
Posted:
March 01, 2018

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Stanley MJ Baker

*** ****** **. ● Madison, AL ***58

● C: 949-***-****

ac4nua@r.postjobfree.com

www.logicalsolutionsllc.biz

Lean Sensei

Lean Sensei with 30 years of experience and consistent success in achieving Safety, Quality, Cost and Delivery goals. Able to guide and lead highly skilled, cross-functional teams in the design, development and launch of leading-edge solutions and processes, including Lean Manufacturing, Total Quality Management, Operational Excellence and Six Sigma.

● Value Stream Mapping ● Overall Equipment Effectiveness

● Standard Work ● 6S Methodology

● Problem Solving & Root Cause ● Coaching & Mentoring

● Visual Management ● Continuous Improvement

● Self-Managed Work Groups ● Waste Stream (Green)

● Metrics: FPY, OTD & IT ● Mistake-Proofing

● Quick Changeover (SMED) ● Total Productive Maintenance

● Lean Conversion ● Ergonomics

● Floor Plan – Spaghetti Flow ● KanBan

● Kaizen Events ● Model Cell

Core Compencies

● Project Planning & Scheduling ● Quality Assurance Control & Standards

● Budget Planning & Administration ● Project Management (PMBOK)

● Operations & Reengineering ● Start-UP & Turnaround Operations

● Supply Chain Management ● Problem Solving & Change Management

Sales Growth: Play key role in increasing sales via acquisitions, mergers, and effective marketing, sales and operations management strategies.

Product Development: Led teams in the introduction of new products to meet design criteria for manufacturability, testability and excellence. Including ROHS & WEEE.

Operations Reengineering: Increase efficiencies by factory layout, reducing setup times and number of changeovers. Increase capabilities with Overall Equipment Effectiveness; Preventative, Predictive and Productive Maintenance of equipment.

Performance Improvements: Improve on-time delivery by implementing project planning system based on team work, quality and continuous improvement goals. Develop capacity man-loading requirements to further enhance on-time delivery initiatives and forecasting needs.

Logical Solutions, LLC – Madison, AL (April 2003 – Present)

● Owner/Founder/Sr. Consultant: Define, design and implement continuous improvement projects in support of Customer Operations to meet Safety, Quality, Cost & Delivery goals and objectives.

Electro Switch/Digitran – Rancho Cucamonga, CA (2017 to 2018)

● Lean Champion: Support Lean Management System process improvement efforts for both the Digital & Rotary Low Volume/High Mix Aircraft Switch value streams. Lead projects for Materials, Engineering, Manufacturing, Quality Control and Facilities. Developed plan based on current state eVSM, cycle time and customer takt time, as well as, order history. Set-up min/max levels for all raw parts and KanBan pull system for finished parts. Reduce cycle times by 50% with Standard Work & Universal Setups. Increased first pass test yields from 70% to 85% with In-line Testing & Real Time Feedback. Developed KPI for Overall Equipment Effectiveness, On Time Delivery, Inventory Turns, First Pass Yield and Build to Schedule.

AVCORP Composite Fabrication – Gardena, CA (2016 to 2017)

● Lean Champion: Support Lean Management System process improvement efforts for both the F-35 & 787 High Volume/High Mix Fiber Composite Fabrication value streams. Lead projects for the ATL, AFP, Gerber, Hand-Layup, Autoclave, Machining and NDT centers to meet customer recovery plan. Recovery plan/timeline based on current state eVSM lead time, individual cycle times and future takt times. Setup recovery teams based on cross functional support and kaizen bursts to drive rapid improvements. Automatic Fiber Placement KPI was changed from lbs./hr to Inches/hr and programs revised to take full advantage of bi-directional placement of fiber. (4) Machine production schedule was revised to meet customer demand and actual shipping mix/volume.

Consolidated Container Corp. – Atlanta, GA (2015 to 2016: Contract)

● Lean Champion: Support Lean Management System process improvement efforts for both the HDPE & PET resin High Volume/High Mix Multi Plant Blow Molding value streams. Lead projects for the Shuttle, Reciprocating and Wheel platforms to meet customers Overall Equipment Effectiveness Glidepath. Lead, Teach and Mentor each facility on identifying and executing Daily Team Maintenance plan based on Best In Class Standards and Plant Value Creation Analysis.

Parker Hannifin, Parker Aerospace CSD – Irvine, CA (2013 to 2015: Contract)

● Lean Specialist: Support Lean Management System process improvement efforts for the Cargo, Commercial, Electronics, Fighter & Helicopter Low Volume/High Mix Hydraulic Valve value streams. Lead projects in the Assembly & Test areas of each cost center. Developed & executed facility plan for one piece flow based on part family matrix. Reduced overall footprint and relinquished 10,000 sq. ft. of floor space for the addition of two FCSIL.

WS Packaging Group – Fullerton, CA (2012 to 2013: Contract)

● Lean Champion: Support Lean Management System process improvement efforts for both the Prime & Multi-Vision construction Low Volume/High Mix Narrow Web Flexographic Printing value streams. Developed Current State eVSM, Floor Plan (Spaghetti Flow), Capacity Analysis and Staffing plan to assess capability to meet company goals & objectives. Perform Kaizen events for TPM, VRK, SMED, Lean Conversion & Model Cell with Standard Work. Developed KPI for Overall Equipment Effectiveness, On Time Delivery, Inventory Turns, First Pass Yield and Build to Schedule. Implemented solutions to standardize equipment by width, stations and process (UV/WB). Reduced initial set-up time, make ready footage and overall MSI. Optimized Ink Mixing area with new layout and improved communication. Restructured Kitting area based on Takt Time of Press requirements to One Piece Flow. Initial impact of $6M/yr, Future State with consolidation should be in excess of $20M/yr.

Northrop Grumman Aerospace Corp. – El Segundo, CA (2008 to 2012: Contract)

● Lean Specialist: Support Affordability process improvement efforts for both the F/A-18 & F-35 High Volume/High Mix Fiber Composite Fabrication value streams. Lead projects for Kitting, Simple Skins, Complicated Skins, Ducts, ATP, Autoclave, Breakout, PMM & AUSS areas to meet customers recovery plan. Recovery plan/timeline based on current state eVSM lead time, individual cycle times and future takt times. Setup recovery teams based on cross functional support and kaizen bursts to drive rapid improvements. Automatic Tow Placement (Viper 1200) KPI (Operation Factor) of 12 and cycle time of 12 days (machine faulted out once every 6 min.) All minor defects repaired, programs optimized, improvements made, operators & technicians trained, standard work put in place, pre-fight checklist established, daily, weekly and monthly PM’s performed. Op Factor of 3.5/cycle time of 3.5 days. Project Awarded NGC President’s Award.

Futronix, Inc. - Homosassa, FL (2005 to 2008: Contract)

● Acting Director of Operations: Oversee core business and operational development functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) within Contract Electronic Manufacturing (CEM) for circuit card assembly (CCA). Implemented one piece flow, quick change-over’s, visual management, lean metrics and 5S. Lead New Product Introduction Team to meet design criteria for DFM, DFT and DFX; including ROHS & WEEE. ISO-9001:2003

Boeing, IDS, SOF, Aerospace - Crestview, FL (2003 to 2005: Contract)

● Sr. Industrial Engineer – Lean Manufacturing Focal: Developed Hanger Layout for (4) AC-130 Gunship’s, equipment, tools and personnel utilizing 3P process. Developed, maintained and optimized Bar Chart’s for each aircraft, employing lessons learned, reducing lead-time by six months for each. Delivered & Presented Earn Value Metrics for Planning and Manufacturing to Sr. Management. ($540M program)

Mid-South Electronics - Gadsden, AL (2000 to 2003)

● Operations Manager: Oversee core business and operational development functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) within electronic manufacturing (CCA), wire & cable, plastic injection molding, metal stamping and box-build. Introduced One Piece Flow, reduce cycle times by 50% (Work standards & universal setups) and increase first pass test yields from 70% to 85% (In-line testing, real time feedback) by developing Value Stream Map, relaying out factory, organizing various departments, developing Master Schedule, introducing CFM, implementing TPS/Lean Manufacturing techniques, working too ISO9001, IPC-610/620 & J-STD.

Qualcon – Flowery Branch, GA (1996 to 2000)

● Manufacturing / Engineering Mgr. Develop Quality Manual, Procedures, Work Instructions and Forms per ISO9001. Facilitate New Product Introduction, Map and Define Processes, Define Product Flow, Develop floor plan layout for Continuous Flow Manufacturing of Circuit Card Assemblies (CCA). Create and Optimize Programs for SMT & PTH equipment. Implemented CFM, Lean Manufacturing, Team Building, Problem solving, 5S, & IPC-610 Rev. C. ISO9001 Registration Received 08/98

Vitel Technologies – Norcross, GA (1992 to 1996)

● Sr. Manufacturing Engineer: Initial factory layout, Order and install Fuji SMT equipment. Lead engineers, technicians and production associates over two shift operation on lean manufacturing, 5S and IPC for CEM of CCA. Develop Quality Manual, Procedures, Work Instructions and Forms. ISO9001 Registration Received 09/95

AVEX Electronics – Huntsville, AL (1989 to 1992)

● Manufacturing Technician / Engineer: Develop SMT & PTH machine placement programs, reflow oven and wave solder profiles. Teach and mentor machine operators. Develop work instruction and process control documents per ISO9000 and IPC standards. Perform regularly scheduled maintenance on machines, feeders and peripheral equipment for Contract Electronic Manufacturer (CEM) of Circuit Card Assemblies (CCA).

SCI – Huntsville, AL (1984 to 1989)

● Manufacturing Technician: Develop SMT & PTH machine placement programs, reflow oven and wave solder profiles. Perform regularly scheduled maintenance on machines, feeders and peripheral equipment for Contract Electronic Manufacturer of Circuit Card Assemblies (CCA).

Education & Credentials

Certificate of Completion Microsoft Project 2001

Certificate of Completion Universal 4795/4796 HSP Prog. 2001

Certificate of Completion Universal 4681/4688A GSM Prog. 2001

Certificate of Completion Lean Manufacturing Champion 2000

Certificate of Completion Theta Prog., Maint. & Cal. 1997

Certificate of Completion Fuji FCP6 Maint. & Cal. 1997

Certificate of Completion Panasonic MVIICA Prog. & Maint. 1996

Certificate of Completion Philips CSM84VZ Operation 1995

Certificate of Completion Philips CSV84VZ Maintenance 1995

Certificate of Completion Universal 6241B/C Op., Prog., & Maint. 1995

Certificate of Completion ISO / SPC / TQM 1993

Certificate of Completion Fuji FCP4 & GSP Maint. & Cal. 1992

Certificate of Completion Fuji FIP & FGL Maint. & Cal. 1992

Certificate of Completion Fuji MCS/2 Prog. & Operation 1992

Certificate of Completion Good Mfg. Practices 1992

Certificate of Completion Contact Systems CS400D Prog. & Maint. 1991

Certificate of Completion Siemens HS180 Op. Prog. & Maint. 1991

Certificate of Completion Dynapert MPS-318 Phase I & II 1991

BS Mfg Eng. Tech Jacksonville St. 1989

AS Electronics Shoals Community College 1987

HS Diploma Russellville, AL 1984

Certificate of Completion Drafting 1984

References

D.M. Jones Avcorp 310-***-**** 3 Yrs. GM

Justin Below Parker 210-***-**** 6 Yrs Lean

Eric Victor Parker 949-***-**** 6 Yrs Lean

Joe Bailey NGC 760-***-**** 9 Yrs Lean

Lazlo O. NGC 310-***-**** 9 Yrs Eng.

Organizations

SMTA 2002

American Society for Quality Control 1995

Software

Microsoft Word, Excel, Outlook, Project, Power Point, Visio & Access.

CAD/CAM: UniCam, FuijCam, Cimbridge, Circuit Cam.

Value Stream: eVSM (Electronic Value Stream Mapping)

CMMS: M2M & Maximo



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