Manager Lean Manufacturing

FRED KOCH, P.ENG. MBA

*-** ****** **, *****, ON N3L 0C6

Cell: 519-***-**** ********@*****.*** ca.linkedin.com/in/kochfred

PROCESS-ORIENTED MANAGER

Safety Quality Process Improvement Troubleshooting Team Building

Proven track record, transforming sites to sustained profitability. Effective in engaging the local team

in applying lean six sigma tools such as value mapping, kaizen, spaghetti mapping, Kanban pull

systems, and SMED to develop and implement a future state that is customer- centered, achieving

improved key indicators and cost reduction initiatives. Hands-on problem solver with strong foundry,

machining and assembly experience, excelling in new product innovation and global sales

development. Consistently achieves improvement in customer satisfaction, increased throughput,

reduced cost, and greater profitability.

PROFESSIONAL EXPERIENCE

PATRIOT FORGE 2014-2015

Nuclear qualified open die forge shops with range of Hammers and Presses, integral heat treat facilities,

rough and finish machining on site. Processing full range of specialty steels, corrosion and heat resistant

alloys.

Manufacturing Manager, Paris ON

Start-up of reclaimed Press. Integrated Press into production.

Developed and implemented departmental accountability and performance tracking system.

Championed safety culture improvement. Implemented near miss reporting and analysis.

Developed future state map and flow of material through machine shop to prepare for installation

of new machines in preparation of foreseen shift in product mix with the addition of Press.

WESCAST INDUSTRIES INC., BRANTFORD, ON 2012-2014

Wescast is the largest global manufacturer of cast exhaust manifolds and turbocharger housings for

passenger cars and light trucks, with multiple sites world- wide.

Foundry Process Specialist, Corporate Technical Group, servicing all sites

Reduced material costs by 18% through implementation of secondary materials in production of

heat resistant stainless.

Developed and implemented means to reutilize cut-off fines; first plant recouped $400K annually.

Led scrap reduction from 34% to single digit at recently opened plant by implementing new

processes. Continued to support the specialty stainless plant team, to further reduce scrap to

below 5%.

Troubleshot European furnace failures. Identified and eliminated source of premature failure

which resulted in a 30% capacity increase.

Trained multisite employees on drivers and modifications needed to produce stainless in the iron

foundries.

Assisted Magna simulation team to change from a theoretical investigation to a production

tooling optimization method. Reduced time for successful first-off casting by 50%.

Fred Koch ********@*****.*** Page 2

FLOWSERVE CORPORATION 2003-2012

Largest multinational pump supplier to the oil industry with world wide operations and 15,000 employees.

General Manager, Flowserve CAC, Kitchener, ON 2010-2012

Large stainless steel foundry was purchased from the Courts in need of a total rebuild and

implementation of a “quick-ship” customer-focused culture.

Achieved 4.5 years with zero Lost-Time Accidents (LTA) and recycling of all by-product streams

as a result of implementing a safety and environmental focus.

Realized $1.0 million in annual savings by eliminating the need to store legacy tooling.

Introduced scanning (digitization) and produced temporary Foam tooling from digital files as

needed.

Started up FastCast foundry, producing castings without patterns, from surface files, in four days,

utilizing three d print technology.

Reduced cost of poor quality (COPQ) by 78% and improved on-time delivery by 211% through,

employment of flow control to gating systems.

General Manager, Flowserve Pump, Brantford, ON 2003-2010

Responsible for Profit & Loss (P&L) in a 150 employee unionized environment producing multiple

centrifugal and screw pumps for oil and resource industry. Accountable for design, sourcing, machining,

assembly, performance testing, and packaging for field installation.

Achieved 140% increase in throughput and a 300% increase in profitability by implementation of

Lean manufacturing initiatives, which debottlenecked plant and created flow.

Managed multi-year $8 million R&D program with Shell Oil. Developed, manufactured and full-

scale tested high pressure screw pump for subsea multi-phase use, exceeding traditional boost

by 300 percent.

CRANE VALVE GROUP, BRANTFORD, ON 1998- 2003

Plant Manager

Accountable for P&L in a unionized plant with 200 employees. Included Foundry, Machine Shop,

Assembly, Warehousing Operation and Original Equipment Manufacturer (OEM) sales.

Generated a $4 million Operating Income (OI) turn around by:

83% scrap reduction, utilizing solidification modeling

Eliminated $2 million past-due shipments with implementation of a Kanban pull system

Added $5 million incremental OEM, utilizing freed up capacity

Operational matrix improvement by utilizing Lean manufacturing and Kaizen:

On-time improvement from 45% to 95%

83% inventory reduction

48% productivity improvement

PREVIOUS EXPERIENCE IN MANUFACTURING, RECYCLING AND ENVIRONMENTAL

EDUCATION AND PROFESSIONAL DEVELOPMENT

MBA, McMaster University, Hamilton ON

B Eng. Metallurgical Engineering, McMaster University, Hamilton ON

Industrial Chemist

Six Sigma Green Belt Certification

Lean Manufacturing University of Tennessee

Kaizen Leader Training

AFFILIATIONS / ASSOCIATIONS / MEMBERSHIPS

Fred Koch ********@*****.*** Page 3

Member, Ontario Society of Professional Engineers (OSPE)

Past Director, American Foundry Society (AFS)

OPTIONAL INFORMATION

Past Instructor, Foundry and Metallurgy, McMaster University and Mohawk College

Ongoing Contributor to Industrial Recycling Program, Colorado School of Mines

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