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Plant Manager, Engineering Manager, Continuous Improvement, Quality

Keller, Texas, United States
December 28, 2018

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PE, LSS Black Belt

817-***-**** (mobile)


Mr. Rhodes has more than 20 years of industrial engineering and business management experience. In industry, he has held positions ranging from Plant Manager to Engineering Manager, to Quality Manager, Lean Leader and Maintenance Manager.

Mr. Rhodes accomplishments started early in his industrial career as he worked his way through college as a co-op student. During that period, he worked his way through college being employed by Gould, Inc. and Union Carbide in Cleveland, OH. While working in a junior industrial engineering position, he helped to: plan and implement an incentive pay program; reduce manufacturing floor space by 30%; develop a new product; and increase productivity by 50%. After graduation, he was employed for 8 years as an associate and then senior industrial engineer with Allied-Signal Aerospace where he gained experience in reducing cost in many manufacturing processes including electro-mechanical assembly, parts finishing, plating, painting, CNC machining, plastics molding, and electronic surface mount operations. He also assumed a leadership position in the company’s Quality Circle program.

He joined the Kansas City Goldblatt Division of Stanley Tools in 1990 as Engineering Manager, where he was responsible for engineering design and development, quality control, tool room, and manufacturing engineering. While with Stanley, he improved paper conversion processes by adding in-line labeling machine on the re-rolling process, increased quality and lowered manufacturing costs by spearheading the development and implementation of a new powder coating system as well as a new state-of-the-art robotic grinding system. The grinding system alone led to a $350,000 savings on capital equipment procurement. He also procured a patent on the equipment used for a new texture spraying process.

Mr. Rhodes also led the efforts to implement cellular manufacturing techniques within the plant that resulted in dramatic inventory reductions and an increase in the inventory turn rate to 50. He has established moving production lines with aircraft manufacturing companies as well as lead over 25 Kaizen events to help reduce production costs and eliminate waste.

He has worked on numerous projects since entering the consulting profession in 1996. His focus has been on training companies in manufacturing techniques. Manufacturing cost reduction, and solving technical problems associated with manufacturing. Projects have included cost reduction, information systems planning and implementation, Lean Manufacturing Implementation, workforce training, project management, data base cost systems and Kanban systems implementation, preparation for ISO 9000 certification, design of manufacturing cells and developing plant layouts for minimizing materials handling costs. Brian has implements a moving production line for a family of Hawker Beechcraft aircraft while implementing $1.2MM in cost savings through the use of Kaizen events.

Brian Rhodes is a licensed and registered professional engineer. He is also a Lean Six Sigma Black Belt through Lean Manufacturing Consortium. He earned his bachelors degree in Industrial Engineering at Cleveland State University and his MBA at Rockhurst University. He has also been a part time evening adjunct professor at Baker University teaching management science, statistics and quality control.


MBA, PE, LSS Black Belt



Registered Professional Engineer, Lean Six Sigma Black Belt with extensive experience in industrial engineering and business management at small and medium sized companies as well as Fortune 500 businesses. Expertise in Lean Manufacturing, Project scheduling, Process improvement, Process automation, Cost reduction, Plant Layout, Quality Improvement, Sheet Metal Fabrication, Plastics, Painting (Conventional and Powder Coating), Miniature Electro-Mechanical Assembly, Robotics, Soldering, Welding (MIG, TIG and stick), Potting, Electronic Assembly, Heavy Equipment Assembly, Continuous - Roll Paper Processing. NADCAP experience in aviation.


Covia Corp 2018, Continuous Improvement Manager Operational improvement Manager at sand mining and processing facility, Cleburne, TX. Initiate Lean improvement ideas, including 5S, reduction of transportation, KPI’s as well as Kaizen Events and other productivity improvement methods.

PENHALL CO. 2017 Productivity Manager. Highway and Bridge construction and demolition company, Dallas, TX

Internal consultant, managing a plant startup, and reconstruction project as well as improving operations in the field construction projects. Worked with field operations across the US, and helped to optimize and standardize the processes to improve operating costs and profits. Worked on improving office procedures like contracts, A/P, and systems as well.

AMERICAN STANDARD Fixtures Company, Quality/Process Manager (Contract Position), Dallas Tx. 2016

Responsible for incoming material quality as well as production quality at walk-in bathtub manufacturer. Work with outside vendors to improve processes and maintain quality standards. Consolidated vendor process for cost savings and process flow improvement. Set quality metrics at facility to improve internal quality. Evaluated and improved supplier product quality to improve the performance of our Walk-in tubs.

PECO / FACET, Mineral Wells, TX 2012 - 2015

Manager, Continuous Improvement and Maintenance

Develop lean initiatives and handle maintenance on 345 person, 17 building, 47 acre site and preventative maintenance program and initiated training and implementation for 5S program plant wide.

Kaizen event coordinator for plant process improvement and cost savings of over $2MM.

Managed Capital Projects budget of over $2MM, implementing numerous capital projects saving over $750K per year.

Implemented Continuous Improvement projects utilizing over 8 Kaizen events in 18 months.

Sustaining equipment averaging over 25 years old, maintaining production schedules implementing TPM

Implemented preventative maintenance program in the machine shop.

GARDNER DENVER, Fort Worth, TX 2011 - 2012

Project Leader

Responsible for developing processes, product and building requirements for a $3.2 Million project to develop a new product line.

Identification of process equipment for new product, purchasing with capital, and preparing buildings for new equipment and proving process.

Brian Rhodes 817-***-**** (page2)

HAWKER BEECHCRAFT, Little Rock, AR (Contract position) 2010 - 2011

Lean Leader

Managed Kaizen events to help save the company $3.5 Million in cost reductions. Holding Kaizen events bi-weekly for 6 month period in various areas to come up with ideas (both long term projects and Just-do-it projects). Implement moving line for Aircraft Interior installation.

Establish a moving production line for aircraft assembly utilizing Visio production schedules developed over a period of 3 months with production trade personnel.

Utilizing Kaizen events and Microsoft Project, documented over $2.5MM in cost savings in aircraft production assembly areas for Hawker/Beechcraft jet production.

Sr Lean Engineer, Vought Aircraft, Dallas, Texas 2008 – 2010

Lean Leader on Gulfstream 550 wing production line. Responsible for saving 15% on span time as well as over $300K per year on costs. Team leader on equipment improvement projects as well as downtime reduction. Six Sigma Green Belt as well as Lean Leader Certification.

Implemented Visual Manufacturing techniques, using standard production manuals and timing flags on the wing production floor.

Utilized 5S methods to develop point of use tools on the production floor.

Implementation Leader – BNSF Railway – 2006 - 2008

Value Engineering Leader responsible for making improvements in railroad velocity for yards and over 30,000 miles of railway tracks across the US. Using Lean and 6-Sigma tools to reduce costs and improve railcar velocity and flow through yards and across the country.

Plant Manager – Novatron Corp. 2005 – 2006

Manufacturer of Wiring harnesses and dashboards for boating industry. Hired to run the plant while on assignment as a Lean consultant. Implemented Lean Manufacturing and managed facility of 150 persons, including engineering, maintenance, manufacturing, and purchasing.

Sr. Consultant, Technical Consulting Network 2003 to 2005.

Manufacturing consultant, assisting companies in Lean Manufacturing, plant layout and team building. Projects include: Lean Coordinator for local manufacturer of rupture discs, setting up programs and measurements for lean implementation. Interim Engineering Manager for airport pushback tractor company, improving the design of existing tractors as well as new hybrid models. Lean training for lawn mower plant, helping to develop a new plant layout with process flow data.

Regional Sales Manager – Symplex Software Systems –2002 to 2003– Sales manager for ERP Manufacturing software sales and service company with territory in the Midwest. Company went out of business.

Engineering Manager – Donaldson Company – 2001 Manufacturing Engineering Manager of $45M company of Filtration equipment for the automotive industry. Responsible for Process improvement, Tool Room, environmental control and reporting, and Capital Equipment acquisition. Implemented Setup reduction program to reduce setup by 25% at plant level to meet $2M budget reduction and improve changeover and plant process throughput. Process Improvements resulted in over $450K savings per year.

Mid America Manufacturing Technology Center – Engineering/Manufacturing Consultant 1996-2001


MBA, Finance and Management - Rockhurst University, Kansas City, MO

Bachelor of Science Industrial Engineering, Cleveland State University

Professional Engineer, Lean Six Sigma Black Belt, Lean Manufacturing Specialist

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