Continuous Improvement Manufacturing

EXECUTIVE PROFILE

Senior operations executive and champion for lean manufacturing offering extensive success implementing world-class, progressive manufacturing strategies, leading turnaround efforts, and strengthening financial results in global multi-site manufacturing operations. Highly accomplished in strengthening competitive advantage by reducing costs of products and processes. Experienced in plant start-ups, acquisitions, consolidations and layout designs. Accomplished in retail store openings, start-ups, and relocations.

Proven change agent and effective leader during periods of organizational changes and financial challenges. Special talent for gaining employee involvement and motivating union and non-union labor forces to engage and work cohesively in achieving productivity, quality, and safety objectives. Known particularly for commitment to opening cooperative bridges of communication between management and work teams.

AREAS OF EXPERTISE

Derse Inc. Dallas Division, Coppell, TX….2014 – Current

Division Operations Director

Recruited by executive management of this $150M international Face 2 Face marketing and exhibit company to improve the overall Cost of Sale for the $30M Dallas division. Responsible for managing the Budget/P&L, developing communication improvement between Production and Sales, developing the continuous improvement program, work with Corporate Operations to develop job specific training for accounting, project management, logistics and production.

Developed a new leadership team in 3 of the 4 departments reporting directly to me.

Exceeded 2015 projected Sales in excess of $2M.

2015 construction Cost of Sale performed 5% better than projected. 2016 Cost of Sale is one track to perform 2% better than previous year.

2015 net income exceeded projections by $2.3M. 2016 net income is 128% better than projected end of Q2.

Improved production technology with a new CNC and software through negotiating with vendors for exhibit booth. New assets exceeded the cost of production by 73% combined. Total asset increase was in excess of $150K.

Revamped and led team for warehouse organization and mapping. Allowed for a 35% gain in cubic footprint with a return of $.21/cf when leased for storage to divisional client base.

Dallas Division won the most “Financially Improved Division” for 2015.

Trained department management on managing to a budget by utilizing a budget to actual monthly analysis and reporting structure.

Worked with Corporate “C” level team to support new leadership training agendas for multiple divisional application.

Trinity River Furniture Mfg, Decatur, TX…. 2008 – 2014

Chief Executive Officer and Operations Manager

Personally financed and developed owner operated business. Managed all critical aspects of the manufacturing and retail operations, negotiated materials purchases, established lean metrics and worked to Just in Time environment. Oversaw, manufacturing production scheduling, quality control and furniture design.

Grew business from inception to multi-state supplier of custom manufactured furniture.

Increased productivity 91% while maintaining staffing levels.

Maintained profitability of 47% per year by operating on a no credit, cash basis with all vendors and clients.

Achieved a 98% first pass quality metric through Lean Poke Yoke processes.

Reduction of manufacturing facility footprint by 67% in 6 months by developing a kaikaku “radical change” in manufacturing processes.

Luxury of Leather, Carrollton, TX….2006-2008

Director of Operations

Reported directly to the owner’s, of this privately owned, furniture manufacturing and retail company. Manage the daily production of 40 employees working manufacturing.

Tasked with the implementation and training, of lean manufacturing methodologies, throughout the organization. Complete control over P&L for manufacturing. Manage payroll, human resources, accounting, inventory control, distribution and shipping, purchasing and quality control.

Increased retail growth by 133% without increasing manufacturing labor base through improved manufacturing processes.

Decreased labor by 57% in the wood frame fabrication shop, through process & technology improvements.

Increased productivity 91% while maintaining staffing levels as production increased 93%.

Reduced customer lead-time by 66% through Takt-Time based manufacturing.

Reduced material loss by 11% by implementing barcoded inventory management system.

Ashley Furniture Industries, Inc., Ecru, MS….2003 – 2006

Lean Site Facilitator

Recruited by the Executive VP of Manufacturing to develop and train the Lean Manufacturing Global Team. Developed all aspects of the Lean Training Modules used globally. Trained and coached all levels of management on Lean Management and Accounting principles. Train all suppliers on Lean Principles and Just in Time production philosophy. Represent the company as public speaker and Lean Expert. Work directly as liaison for all areas of the production processes, from design concept to customer’s home.

Increased distribution from $14m to $25M per week with minimal labor increase.

Tracked global Continuous Improvement Progress through multi-site management of initiatives

Increased material yield by 15% through successful 3P event.

Increased production capabilities by 23% using Kaikaku layout providing production increase in the same footprint.

Increased production efficiency from 113% to 127% through Kaizen & continuous process improvement.

Decreased production lead-time by 9 days through Kaizen & continuous improvement.

Reduced WIP from 24 hours to 6 hours in the Poly Mill Plant through Kaizen & continuous process improvement.

The Boeing Company, Corinth, TX….2000 – 2003

Manufacturing Operations Analyst – Lean Sensei/Consultant

Lead the Lean Enterprise Group in the North Texas Operations. Serve as a consultant to upper executive management on long range planning for new and existing programs. Train Kaizen leaders for multi-sites in North America. Act as liaison for external customers on process improvements, i.e. El Al Airlines, American Airlines, and Bell Textron Helicopter. Train production workforce on Standard Operations, 5S, Set-up Reduction, Continuous Flow, and Waste Elimination.

Saved $964K by reducing WIP from 15 days to 5 days on the 737 program.

Saved $7.6M leading or participating in 50+ Kaizen, 3P, TPM events.

Saved $124K through wire harness connector defect elimination.

Improved cash flow by $3.2M by utilizing production flow based Takt time.

Real Estate Investments, Fort Worth, TX ….1989-2000

President/Real Estate Agent/Loan Officer

Branch Manager recruited as Loan Officer for the Fort Worth Branch. Work directly with developers and home purchasers to establish home loan or construction loans. Represent company at civic and corporate functions as branch spokesperson.

Reduced closing time from 33 days to 18 days through continuous improvement

Increased loan throughput from 17 to 42 loans per month using continuous improvement processes & maintained static labor force

Cantrell Production, Ada, OK….1984-1989

Controller of Companies

Converted accounting system from a manual ledger system to Peachtree Software.

Developed the JIB “joint interest billing” system. Created a 49% decrease in company expenses by allocating investor percentages back to expenses.

Reduced overhead cost by 27% by strategically realigning the candy manufacturing operations leasehold equipment agreements.

Vie de France Corporation, McLean, VA….1984-1987

Senior Accountant

Led fraud billing investigation team. Resulted in $700,000 annual savings globally.

Education

Bachelor of Science (B.S.), Business Administration, University of Phoenix

Continuing Professional Education

Lean Practitioner Certificate – Productivity Inc.

Lean/AIW Leader Certificate – Boeing Lean Enterprise Office, Renton/Everett, Washington

Lean Sensei Certificate – Shingijutsu Consulting, Tokyo, Japan

Competent Toast Master – Toast Master International

Contact this candidate