Charles (Chuck) A. Troll
Professional Summary: Manufacturing professional with over 20 years of experience in a variety of industries. Passionate about helping businesses achieve real results. Expert in ISO-based management systems, process improvement and project management.
Contract Industrial Engineer (9/12 – Present)
Self-employed (www.chucktroll.com) Somerset, PA (Process & Quality Improvement)
Implemented numerous ISO-based management systems with each client achieving certification. Provide ongoing internal audit and consulting services.
Developed various lean manufacturing strategies for several clients. Implemented numerous lean methodologies on factory floors. Achieved deliverables with all projects.
Designed and delivered a hands-on training package introducing lean manufacturing concepts for the Allegany College of Maryland - Somerset Campus.
Guest-lectured on ISO 9001 and supply chain management at a branch campus of the University of Pittsburgh.
Increased throughput & provided facility layout services for a client who produces fabrications for the industrial/commercial service vehicle industry. All production goals were met.
Developed a system of estimating labor standards using internally developed predetermined standards for a client who builds tank trailers for the oil & gas industry. Resulting work was used to operate the business system quote module.
Production Manager (10/08 – 8/12)
Keystone Drill Services Somerset, PA (Compressed Air Boosters – Oil & Gas)
Optimized the output of a $30MM booster packaging, compressor packaging & bit repair/assembly operation. Directed the activities of production mechanics to meet or exceed customer deadlines.
Lead several product development & launch projects. Built cross-functional teams and coordinated their activities to meet or exceed manufacturing readiness milestones.
Forecasted, planned & procured all long lead time components required for assembly. Managed visual floor-stock and VMI programs.
Collaborated with core team members to specify, evaluate, select and implement a corporate ERP system. Business process owner for the service management and production planning modules of SAP. Wrote process manuals and conducted training.
Manager, Industrial Engineering (9/04 – 10/08)
J&J Truck Bodies & Trailers Somerset, PA (Dump Truck Bodies & Trailers)
Coached, developed, and mentored industrial engineers, technicians and co-op students.
Developed & implemented manufacturing processes for new products.
Established a fixed rate, mixed-model trailer assembly line resulting in a 25% reduction in labor.
Revamped an aluminum dump body assembly cell and a truck hydraulics assembly cell. Recorded a combined 40% reduction in labor.
Created and implemented a floor-level performance-based bonus program.
Implemented and maintained 5S concepts throughout two factories.
Manager, Quality & Manufacturing Engineering (2/98 – 9/04)
Sensus Metering Systems DuBois, PA (Gas Meters & Regulators)
Implemented a company-wide continuous improvement program as the Six Sigma & Lean Site Champion and Trainer. Recorded $750K in cost savings and $100K in WIP reduction over two years.
Achieved BASEEFA certification & lead the effort to become the first gas meter manufacturing site outside of Canada to achieve Measurement Canada accreditation.
Implemented ISO9001:2000. Served as ISO Management Representative.
Provided leadership in decision making for operations in DuBois, PA and Monterrey, Mexico concerning quality issues driven by customer, supplier and/or process.
Coached, developed & mentored manufacturing engineers, quality engineers, technicians & inspectors
Coordinated a corporate initiative to outsource several operations and consolidate two facilities into one. Recorded a $300K cost improvement and a 40% floor space reduction.
Planned & managed the sale of a $7MM machining & stamping business. Saved $2MM over a three year contract.
Directed the relocation of sub-assembly operations to an established maquila operation in Juarez, Mexico.
Managed the relocation of a product family and supply chain from the UK to the US.
Developed capital and cost improvement goals for the profit plan with accountability for delivering both. Met or exceeded targets each year.
Other Work Experience
Coordinated and delivered a $1MM cost improvement by improving sheet metal procurement and utilization.
Managed the replacement of a liquid solvent-based paint system with an electrostatic powder coating line. Met or exceeded all project deadlines. Modified work rules and developed labor standards resulting in a 30% reduction in labor.
Developed a system of estimating labor standards using internally developed predetermined standards.
Education: Bachelor of Engineering - Industrial Engineering
Youngstown State University Youngstown, OH