Manager Project

STEPHEN P. STEPHENS, P. Eng.

*** *., ****** **. **, RR 1 Residence: (519)

***-****

Essex, ON Canada N8M 2X5 E-mail (hotmail.com): stephens_essex

Career Highlights

Professional Engineer, with international experience in 7 countries,

designing, building and commissioning 10 manufacturing plants, and

improving many others.

Business acumen includes 20 years in the automotive industry with increased

levels of responsibility from Project Engineering to Plant Manager

(including a Japanese joint venture), with 10 years of consulting in Lean

Manufacturing (Toyota Production System).

Education

World Class Manufacturing (OCAM, Toronto Ontario, Canada)

6 Sigma Green Belt (Villanova University, USA)

LEAN Manufacturing Certification (University of Michigan, USA)

Professional Engineer (Ontario, Canada)

Hon. B.A.Sc. (Mech. Eng., University of Waterloo, Ontario, Canada)

Business Experience

Danfoss, Norborg Denmark

2009 - Present

Global manufacturer of Climate and Energy controllers

Navigator - Global Lean Coach

. Lean implementation specialist, coach Plant Mgrs, Change Agents, and

operators

. Conduct Lean assessments (System Audits, Shop Floor Audits, Full

Potential Mapping audits, etc.)

. Coach plant management on next steps on Lean journey

. Lead shop floor fact based Root Cause Problem Solving and Kaizens in

USA and Mexican manufacturing plants

. Workstation, line balancing and material flow optimizations, over $10

million annual savings in USA and Mexico operations

Chrysler, Auburn Hills Michigan, USA

2003 - 2009

Automotive Manufacturing

Manufacturing / Lean Consultant

. Reviewed North American Car, Jeep and Truck assembly operations and

confirmed, corrected or created over 1,500 SOPs (Standard Operating

Procedures)

. Team member of several Advanced Manufacturing Engineering teams

identifying waste and implementing improvements at several North

American assembly plants (in BIW, Paint, and TCF)- over 1,000 jobs

reduced, savings of about $100 million

. Lean Manufacturing Instructor and Speaker at Chrysler Technical

Training Center, and several North American assembly plants (BRAP,

WAP, WTAP)

Stephen P. Stephens

- 2 -

RWD Technologies, Troy Michigan, USA 2000

- 2002

Manufacturing Consultants. Employees: 1,000

Sr. Lean Consultant

. Chrysler, USA, Canada and Mexico, automotive assembly plants:

- Jefferson North Assembly Plant, Detroit (labour savings ROI of

1,700 %)

- Warren Truck Assembly Plant, Warren (set-up Lean Training Center)

- Toluca Assembly Plant, Mexico (set-up Lean Training Center)

. Ford, USA, Fairlane Technical Training Centre:

(Instructor of: Poke yoke, SMED, 5S, Kanban, PM, SOP's, SPC,

Teams)

. Ford, Canada, Windsor Aluminum Casting, Essex Aluminum Casting

(Coached on: Value Steam Mapping, Lean Audits, Team improvements)

TGI Group, Windsor, Ontario 1997 - 2000

Automotive Manufacturing Consultants. Employees: 100

Project Manager (Sr. Consulting Engineer)

. Team leader of 6 engineers using MOST (Predetermined Time & Motion

Studies) at Navistar International Heavy Truck, Chatham. ROI : 600 %

. Team leader of 15 engineers in problem solving - SPC, DOE, FMEA, and

other Black Belt tools, at Chrysler, Sterling Heights (BIW, Paint, and

TCF )

A.G. Simpson Automotive, Oshawa, Ontario 1996 -

1997

Automotive Bumper Stamping and Chrome Plating. Annual Sales: $150 million.

Employees: 600

Operations Manager

. Responsible for all production operations, including metal

preparation, stamping, welding, chrome plating, polishing and

assembly.

Naylor-Mcleod Computer Training Institute, Cambridge. Ont. 1995 - 1996

Student

. Certified Novell Netware Administrator (CNA)

. Business Programming and Applications Specialist

Bauer Industries Limited, Waterloo, Ontario 1992 -

1994

Automotive Textile Supplier. Annual Sales: $20 million. Employees: 150

Plant Manager

. Championed an employee involved productivity improvement program,

which resulted in an unprecedented up-time productivity gain of 133 %.

. Driving force in the use of Theory Of Constraints to reduce

unscheduled downtime from 37% to 4%, the reduction of operating costs

and the significant improvement of more than tripling productivity,

(240 % gain).

. Turned plant around (drove Net Profit from -12% to +34% of Sales).

White Consolidated Industries, Cambridge, Ontario 1990 - 1992

Appliance Manufacturer. Annual sales: $21 million. Employees: 250

New Product Development Manager

. Facilitated an effective team of 10 group leaders from 4 countries

representing Marketing, Engineering, Production, R&D, and Finance.

Stephen P. Stephens

- 3 -

Woodbridge Foam Corp. (Woodbridge Group), Toronto, Ont. 1984 - 1990

Automotive Interior Supplier. Annual sales: $900 million. Locations: 30.

Employees: 4,500

Plant Manager, Japanese Joint Venture, St. Marys, Ont. 1987 - 1990

. Championed all aspects of plant design, construction, installation,

start-up.

. Sod turning, construction to full volume production in 10 months.

. Achieved prestigious World Quality in 8 months (38 defects/million)

. Exceeded labour reduction goals by 25%.

. Cultivated a union-free labour force, cost avoidance of $800,000 /

year

. Successfully implemented the Toyota Production System (TPS).

Corp. Project Engineering Manager, Toronto, Ontario 1985 - 1987

. Completed construction of 6 auto parts plants on time and within

budget.

. Responsible for all aspects of site selection and preparation,

municipal services, equipment design, procurement, installation, and

start-up.

. Ascended to company authority on Canadian and USA Air Quality Regs.

Corp. Project Engineer, Toronto, Ontario 1984

- 1985

. Completed construction of 2 auto parts plants on time and within

budget.

. Pioneered project control and record manuals, became company standard.

Associations

Team Lean Consultants International Inc., Lean Consultant (freelance)

Business Development Bank of Canada (BDC), Lean Consultant

(freelance)

LEAN Enterprise Institute (LEI), USA, Member

Professional Engineers of Ontario (PEO), Member

Professional Development

Internet Research Techniques (Net Success, Windsor, 2003)

Assertiveness for Leaders (AMA, Toronto, 1999)

Executive Leadership Development (AMA, Toronto, 1999)

M.O.S.T. Certification (H. B. Maynard, Pittsburgh, 1998)

Time Management (Naylor-McLeod, Cambridge, 1996)

Team Building (Naylor-McLeod, Cambridge, 1995)

High Performance Leadership Skills (OCAM, Toronto, 1994)

World Class Manufacturing (OCAM, Toronto, 1994)

Continuous Improvement (OCAM, Toronto, 1994)

Supplier Quality Assurance, Audit Certification (Toronto, 1990)

Activity Based Costing (Toronto, 1990)

Toyota Production System (Japan, 1988)

Computer Skills

Certified Novell NetWare Administration (CNA)

Certified Business Programming and Applications Specialist, MS Office

Pro

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