Lean Manufacturing Manager

* ***** ******, *******, ** V*C *R* 250-***-**** ****.******@********.***

Todd Joseph Butera

Profile

Lean manufacturing expert with 15 years of experience and proven track record of implementing cultural change and delivering financial and operational results

Experience includes lean deployment both internationally and domestically, in brownfield and greenfield sites, for Union and non-Union organizations, and across various industries and cultures

Direct experience working in the Toyota Production System and learning from Toyota experts

Experience

Mar. 2011 to Present

RIO TINTO

Salt Lake City, Utah

Manager of Business Improvement and Asset Management, Kitimat, British Columbia

Manage a team responsible for deploying the Toyota Production System across a $5.0 billion aluminum smelting construction project in Northern British Columbia

Deployed lean manufacturing principles to help drive the on time and on budget delivery of the construction phase of the project

Responsible to drive the problem solving efforts focused on the bottleneck processes which impact the ramp-up of the smelter towards full production of 425,000 metric tons of molten aluminum per year

Manage the deployment of the integrated roadmap to ensure a sustainable transformation through leadership development and employee engagement

Responsible for the design and deployment of the asset management strategy across the site

Lean / Six Sigma Director Europe, Middle East, and Africa (EMEA), Voreppe, France

Led a team of master black belts and master lean practitioners responsible for the deployment of the Toyota Production System across all EMEA locations and the delivery of value through structured problem solving

Developed and deployed a primary metal integrated roadmap aimed at developing leadership capability, driving cultural change, and ensuring sustainable improvement

Redesigned and delivered a lean training program based on deployment philosophy

Deployed a value creation execution acceleration process at all EMEA sites

Designed and deployed a leadership development program across all EMEA sites targeted at developing lean leaders

Jul. 2004 to Mar. 2011

ALCOA

Pittsburgh, PA

Global Lean Manufacturing Consultant, Nashville, TN, Dallas, TX

Responsible for implementing the Alcoa Business System (based on the Toyota Production System) across multiple company locations and industries both internationally and domestically

Worked directly for John Marushin who helped launch the Toyota Supplier Support Center (TSSC), Toyota's internal consulting division within the United States during his time with Toyota

Organized and led the first global focus plant event in mining with the goal of capturing greater than $1/ton in financial results across the Alcoa mining system by moving all locations towards operational excellence

Designed a structured inventory system to help the Cleveland Commercial Wheels Division meet their customer and financial targets

Designed and deployed a “systems kaizen” program across the Alcoa rolled products division

Responsible for developing and deploying agreed upon best practices across 22 global smelters

Regional Lean Manufacturing Consultant, Perth, Australia

Redesigned and delivered lean training program with more focus on business case activities

Coached the pilot team for Lean Training Center in China

Represented the Asia Pacific Region in a global initiative to reduce energy usage by improving heater performance, worth $28 million across 9 refineries and more than $5 million in Australia

Designed and implemented visual factories for major equipment overhauls as a means to capture 77 tons per day in lost production worth approximately $5 million per year

Apr. 2002 to Jul. 2004

DAIMLER CHRYSLER

Kenosha, WI

Area Manager (Lean Specialist)

Led the implementation of the Toyota Production System in the greenfield 3.5L engine plant and the brownfield 2.7L engine plant

Developed and delivered lean training

Partnered with U.A.W. counterpart and worked closely with senior management and Union leadership to deploy the lean manufacturing strategy

Received daily coaching from consultants with over 50 years combined Toyota operations experience

Assisted in the design and negotiations of a new Union contract based on the language used in the Toyota – General Motors joint venture in California

Transformed the Kenosha facility into a learning organization for other Chrysler locations to visit and replicate

Apr. 2000 to Apr. 2002

TOYOTA MOTOR MANUFACTURING

Buffalo, WV

Assembly Line Group Leader

Worked as a core member to launch the first automatic transmission facility for Toyota outside of Japan

Participated in equipment trials in Kinuura, Japan prior to equipment installation in West Virginia

Received direct daily coaching from trainers employed by the sister Toyota plant in Japan

Hired team members for the start-up of the transmission facility

Trained new team members in the fundamentals of the automatic transmission and the Toyota Production System

Directly supervised thirty team members and two team leaders in the assembly of the Underdrive, Differential, Transaxle Housing, Valve Body, and other subcomponents for two styles of automatic transmission

Supervised team through a production ramp-up starting at 30 transmissions per day during production trials to 800 transmissions per shift at full capacity

Aug. 1996 to Apr. 2000

PARKER HANNIFIN

Cleveland, OH

Manufacturing Engineer / Production Supervisor Aerospace, Fort Worth, TX

Core team member of the cycle time reduction project

Coached daily by flow management consultants

Delivered classes in lean manufacturing methodology

Created CQM (continuous quality manufacturing) centers for all production departments

Redesigned the assembly lines to accommodate one piece flow

Responsible for all supervisory and engineering functions in final assembly area

Appointed as warehouse and shipping project engineer in addition to assembly functions

Manufacturing Engineer Tube Fittings, Eaton, OH

Implemented work cells to expedite product flow and reduce set-up times

Contributed savings in excess of $300,000 to the cost reduction program

Provided assistance to the Parker Hannifin Mexico project

Headed a project to purchase and install a robotic chucker autoloader

Education

Aug. 1992 to May 1996

Aug. 2004 to May 2006

Miami University

Colorado Technical University

Oxford, OH

Denver, CO

Bachelor of Science in Manufacturing Engineering

Executive Masters of Business Administration

References

References are available on request.

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