Supply Chain Manager
Resume:
RICHARD J. BARNES
**** ********* ***, ********, ** 61107
aca29s@r.postjobfree.com
CAREER SUMMARY
LEAN SIX SIGMA LEADER with extensive leadership experience and a strong
background in applying people, process and technology to streamline supply
chain operations. Demonstrated performance in:
Lean 6 Sigma Customer Service Flexible Supply Chain Operations
Inventory Management Strategic Planning Change Management
Responsibilities and Accomplishments
Supply Chain Planning and Manufacturing
Designed, developed and implemented supply chain strategic plans, which
included reorganization of the supply chain planning and manufacturing
activities by development of Value Stream Maps. Incorporated Queuing
Theory modeling to better approximate dynamic supply chain interactions.
Managed and improved the supply chain planning effectiveness through
forecasting and Kan Ban planning which improved lead times, inventory turns
and on-time deliveries to six sigma levels.
By applying Quick Response and Lean Manufacturing principles lead time were
reduced, on time deliveries improved while reducing overall inventory
levels.
Maximized asset utilization by lowering overall inventory levels by
effectively using bottleneck operations.
Transformed a traditional manufacturing company to supply chain optimizers;
reducing their product cost structure by over 50% making their supply chain
operations a competitive weapon by outsourcing operations, which didn't fit
the company's core competencies, including sending operations to China.
Warehousing and Distribution
Managed up to 125 associates in distribution activities for at least four
different companies.
Managed detail design of material handling systems, reducing overall cost
structure by 50% by utilizing a semi-automated distribution center that
receives inbound containers into a pick and pack operation to satisfy
customer orders with in the same day. Implemented and integrated a RF
controlled warehouse management (WMS) tool with the company's ERP system.
Reduced inventory and improved inventory accuracy to increase customer
service fill rate.
Logistics and Transportation Management
Managed a regional LTL carrier strategy that reduced logistics costs while
improving on-time deliveries.
Managed and negotiated international ocean container rates to an 8%
reduction while the industry was experiencing a general rate increase of
10%.
Managed Latin American logistics by leveraging a door-to-door air
transportation policy, achieving 50% reduction in US delivery cycle times.
Redesigned excess inventory return procedures and implemented inventory
management tools in Latin America, improving asset utilization
Information systems
Improving effective use of organizations' ERP business system and other
information systems. Practical use of the following ERP systems:
SAP, Oracle, Manage 2000, MAPCS, MFG/PRO and various MRPII's.
Selected and installed various warehouse management systems. Practical
use of the following WMS:
RedPrairie's DLx, HighJump's Warehouse Advantage, Manhattan's LogsPro and
Irista's Stock Master
Reduced planning and procurement activities through automation of
information through Internet portals
Performed system selection and implementation activities of supply chain
execution software (APS, MES & TMS).
New Product Development
Used design for assembly & logistics techniques to redesign finish goods to
perform postponement operations to customize product as close to the
customer. Improving speed to market, fill rates and inventory utilization.
Quality Management
Designed Quality Systems that were instrumental in achieving ISO-9001 and
QS-9000 certifications.
RICHARD J. BARNES - PROFESSIONAL EXPERIENCE
ACCENTURE 2010 to Present
Leading Management Consulting Company in Supply Chain Operations
Manager - Managing delivery of project to transform clients to be
High Performing Companies.
Clients in Industrial Equipment, General Manufacturing, Resources,
and Oil & Gas,
STRATEGIC SUPPLY CHAIN CONSULTANTS 2001 to 2010
Setting strategic course and solving difficult Supply Chain opportunities
for clients through consulting:
President and CEO - Managing business development while serving as
principal on projects.
STRATEGIC SUPPLY CHAIN PLANNING
Caterpillar, Mining and Construction Division - Decatur, Illinois:
While designing and building their incoming component Supermarket, we
developed an execution pull kanban strategy. Having suppliers deliver
replenishment inventory when the components were actually consumed by
manufacturing. Both systemic and manual triggers were used to release
inventory from a blanket PO. The highest volume ten suppliers were
used to start the demand pull. Black belts were assigned to help
these suppliers streamline their supply chain.
Federal Mogul Corporation - Birmingham, Alabama: While performing a
Vendor Managed Inventory investigation and design for their largest
supplier, Rockford Products, I negotiated a low cost per square foot
warehouse space, landed numerous business incentives and persuaded
several of their other suppliers to participate in holding inventory
on their books at this facility to achieve a just in time delivery
goal set by Federal Mogul.
Lava World Inc. - Carol Stream, Illinois: Transformed a traditional
manufacturing company to supply chain optimizers; reducing their
product cost structure by over 50% making their supply chain
operations a competitive weapon by outsourcing operations, which
didn't fit the company's core competencies, including sending
operations to China.
Marquette University- Milwaukee, Wisconsin: Instructor - Teaching
Supply Chain Management courses.
LEAN 6 SIGMA DMAIC PROCESS
Caterpillar, Mining and Construction Division - Decatur, Illinois: Re-
designed their incoming component part Supermarket, part presentation
and delivery methods.
Midwest Express Inc. - East Liberty, Ohio: Redesigned their incoming
components consolidation center for 'just in time' material handling
for two Honda Assembly plants in central Ohio.
STRATEGIC DISTRIBUTION PLANNING
Lava World Inc. - Carol Stream, Illinois: Developed the plan to expand
distribution capabilities in Canada, including negotiations with the
3PL to perform transportation into Canada, cross docking or
warehousing and final delivery of product to the customer. Expanded
distribution capabilities, reduced lead time and improved inventory
turns with the 3PL in the United Kingdom.
Peapod Inc. - Lake Zurich, Illinois: Performed distribution network
and financial modeling to justify a hub and spoke strategy for their
northern Illinois and southern Wisconsin customer delivery service.
Wrote and solicited bids from third party providers to assist in the
spoke network. Spoke depots are being open in Milwaukee, Wisconsin
with another potential spoke located in Chicago proper.
FACILITY DESIGN
Circuit City - Marion, Illinois: Designed their repair center to move
into their distribution center, including repair bench design,
proximity and flow through from receiving to shipping.
John B. Sanfilippo and Son (Fisher Nuts) - Elgin, Illinois: Design
and built their new distribution center and all material handling
of raw material and components into their manufacturing facility at
their newly acquired property in Elgin, IL. Managed their detail
requirements specifications, solicited and awarded bids for these
material handling systems.
Lava World Inc. - Carol Stream, Illinois: Through leasehold
improvements, turned a 155,000 sq. ft. spec warehouse and designed
20,000 sq ft. office space, 10,000 sq. ft. quick response
manufacturing center and a 125,000 sq ft. semi-automated distribution
center.
PRODUCTIVITY IMPROVEMENT PROGRAMS
Lava World Inc. - Carol Stream, Illinois: Improved incoming container
unloaded through an expandable conveyor to a manual palletizing
station.
Power Merchandising Corporate - Delevan, Wisconsin: Managed a
productivity program to re-layout the facility in the most efficient
manner, derive reasonable expectancies, build a labor tracking tool
and then develop methods to capture the data for labor report.
RICHARD J. BARNES - PROFESSIONAL EXPERIENCE Continued
MATERIAL HANDLING ENGINEERING
F. Dohman Company - Germantown, Wisconsin: Updated material
handling equipment to work with a new warehouse management system,
including improving a push arm sorter by improving the acceptable
read-rate through an Omni-Scanner.
Globe Union Inc. - Woodridge, Illinois: Redesigning their distribution
center after a consolidation of product lines.
Midwest Express Inc. - East Liberty, Ohio: Redesigned their incoming
components consolidation center for 'just in time' material handling
for two Honda Assembly plants in central Ohio.
Nippon Express Inc. - Aurora, Illinois: Redesigned their distribution
center which handled several different product lines for Canon.
Designed methods and system to material handle and ship the diverse
product offering while finding synergies to drive down the operating
expenses.
Lava World Inc. - Carol Stream, Illinois: Managed detail design of
material handling systems utilizing a semi-automated distribution
center that receives inbound containers into a pick and pack operation
to satisfy customer orders in the same day.
SUPPLY CHAIN DIAGNOSTIC AND BEST PRACTICES
Con-Tech International - New Orleans, Louisiana: Performed an
operational audit and assessed where significant improvements could be
made their supply chain operations.
F. Dohmen DDN - Memphis, Tennessee: Performed an operational audit and
assessed where significant improvements could be made their supply
chain operations.
Mabis - Waukegan, Illinois: Performed an operational audit and
assessed where significant improvements could be made their supply
chain operations.
Troustel Inc. - Lake Geneva, Wisconsin: Performed a supply chain
diagnostic and assessed where significant improvements could be made
their supply chain operations.SUPPLY CHAIN SOFTWARE SOLUTIONS
AT&T Mobility - Memphis, TN, Managed enhancements in RedPrairie's DLx
product.
Avnet Logistics - Phoenix, AZ, Managed implementation of RedPrairie's
DLx product.
F. Dohman Company - Germantown, Wisconsin: Designed and managed
Manhattan Associates' LOGS PRO (WMS) integration into their material
handling systems and ERP.
ITT Industries - Fort Wayne, Indiana: Investigated requirements,
process mapped and developed specifications for a Manufacturing
Execution System.
John B. Sanfilippo and Son (Fisher Nuts) - Elgin, Illinois: Assisted
in the design, selection and implementation of their new warehouse
management system.
Lava World Inc. - Carol Stream, Illinois: Implemented and integrated
HighJump's Warehouse Advantage warehouse management (WMS) tool with
the MHE and ERP.
TRANSPORTATION SYSTEM DESIGN
Lava World Inc. - Carol Stream, Illinois: Managed a regional LTL
carrier strategy that reduced logistics costs while improving on-time
deliveries. Managed and negotiated international ocean container
rates to an 8% reduction while the industry was experiencing a general
rate increase of 10%.
Mannington Mills - Salem, New Jersey: Developed a mathematical model
to assess where their distribution activities were cost effective or
not. Designed a plan to improve the cost effectiveness of their
distribution activities, while improving customer delivery metrics.
Peapod Inc. - Long Grove, Illinois: Through modeling developed a hub
and spoke distribution network to minimize costs while maximizing
customer service.
ROCKFORD PRODUCTS CORPORATION, Steering and Chassis Group, Rockford, IL
2000 to 2001
Predominant QS-9000 leader of cold-headed products for the Automotive and
After Market, Industries. Reason for leaving was due to the loss of
customer requirements that I was specifically hired for.
Assistant General Manager and Director of Supply Chain Operations
Applying Dynamic Operations principles to improve Supply Chain
performance - reducing cycle time, improving on-time delivery, improving
quality while reducing their cost structure.
RICHARD J. BARNES - PROFESSIONAL EXPERIENCE Continued
MAGNETEK, DRIVES and SYSTEMS, New Berlin, WI 1999 to 2000
Second leading manufacturer and value-added re-seller of motor drives and
drives system in North America. . Reason for leaving was due to the sale
of the general purpose drive business to their brand label manufacturer.
Director - Supply Chain and Information Management 1999 to 2000
Director - Logistics 1999
Designed, developed and implemented supply chain strategic plans, which
included reorganization of the supply chain planning and procurement
activities and development of an information system strategy to
effectively use their ERP systems with Internet portals.
ARTHUR ANDERSEN, LLP, Milwaukee, WI 1998 to 1999
Leading professional services firm. Reason for leaving was the MagneTek
opportunity.
Manager - Supply Chain Business Consulting
ROCKWELL AUTOMATION, Milwaukee, WI 1989 to 1998
Leading ISO-9001 manufacturer of control and automation equipment.
Reason for leaving was the Andersen opportunity.
Logistics Manager - Latin America 1997 to 1998
Managed and improved the supply chain planning effectiveness through
forecasting and safety stock planning which improved lead times,
inventory turns and on-time deliveries to six sigma levels. Managed
overall logistics by leveraging a door-to-door air transportation
policy, achieving 50% reduction in US delivery cycle times.
Logistics Distribution Engineering Manager 1996 to 1997
Managed the technical aspects of the distribution center which included
information systems, maintenance and continuous process improvement.
Logistics Project Manager 1994 to 1996
Managed the project to study a centralized distribution strategy,
performed the distribution network model to locate it in the geographic
area, and then lead negotiation of business incentives to locate in
Champaign. Managed a green field and white paper distribution center
design. Conceptual/detail design and implementation of a tote routed
conveyor material handling system through three level pick modules with
weight scale quality pick verification to both carton and pallet pack
sortation systems for a new centralized distribution center. The
facility design provided the flexibility to accommodate a 100% SKU
growth within the existing system over the first 5 years of operation.
The facility also has the capacity for a 50% volume growth with the
addition of a third pick module. A one-year payback was realized with
this system. Managed the integration of Irista's Stock Master (WMS) to
the tote routing conveyor and sortation mechanisms.
Project Engineering Supervisor 1992 to 1994
Managed the quick response manufacturing cell until the need to improve
warehousing and shipping came about because this cell could manufacture
to customer want date but the material movement and shipping needed to
be streamlined.
Project Leader 1991 to 1994
Through lean and quick response manufacturing principles developed a
configure to order flexible manufacturing cell that prioritized and
assembled to order IEC motor starters based on customer want date.
Senior Industrialization Engineer 1989 to 1991
As a new product/process industrialization engineer, I introduced
several new products to their low cost northern Wisconsin facility.
Assisted in their ISO 9000 documentation and certification.
EDUCATION/TRAINING
M.B.A. - Operations Management; Marquette University; Milwaukee Wisconsin
M.S. - Manufacturing Systems Engineering, Business Management; University
of Wisconsin - Madison
B.S. - Electrical & Computer Engineering; University of Wisconsin - Madison
Numerous courses and seminars including:
Black Belt/Lean-6 Sigma, APICS CPIM, Oracle Supply Chain Planning, Quick
Response Manufacturing
Council of Logistics Management Conferences,
Warehouse Education and Research Council Conferences
High Performance Leadership & Assessment, Competing through Speed in
Manufacturing & New Product Introduction
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