Six Sigma Professional Experience

David Ayers

**************@*******.*** M: 720-***-**** 10066 Sedalia St, Commerce City, Co 80022

Senior Operations Leader

PROFILE

Senior Operations Manager with over 25+ years of experience leading production and repair operations in Aviation and Transportation business segments with focus on quality assurance and continuous improvement. Demonstrated leadership in operations utilizing Lean Manufacturing and Six Sigma methodology. Proven success in coaching and leading diverse teams. Thrive in all environments with a specific expertise in union environments including contract negotiations. Areas of expertise include:

AREAS OF EXPERTISE

Quality Control

Lean Manufacturing

8 Step Problem Solving

Six Sigma

Manufacturing Process

Visual Management

Value Stream Mapping

Aircraft Engines

Process Improvement

Locomotive Mechanical

5S

PROFESSIONAL EXPERIENCE

General Electric Company

Senior Site Leader – Denver Colorado 2013 – Present

Manage customer (Union Pacific) Locomotive Repair Facility located in Denver Colorado. Responsible for Safety, Quality, Labor and Production. Manage customer workforce of ~ 180 union employees and GE team of 17 salaried employees. Implement customer programs using UP Way methods, Total Safety Culture.

Drove labor efficiency to a 5,000 hour reduction in straight time and 2000 reduction in overtime.

Drove standardization of maintenance line to reduce overall cycle times ie. Standard Work, Point of use material and tooling. Cycle was reduced from 86 hours to 65 hours.

Lead completion of 191 locomotive overhauls with no injuries and within labor metric.

Led formation of local safety team (Critical 5) made up of Union Leaders to identify and address safety concerns/behaviors in an effort to drive workforce involvement in overall plant safety.

Operations Leader/Site Leader – Morrill Nebraska 2011 – 2013

Manage customer (Union Pacific) Locomotive repair facility located in Morrill Nebraska. Responsible for Safety, Quality, Labor and Production. Manage customer workforce of ~ 85 union employees and GE team of 10 salaried employees.

Using lean, established process to perform locomotive scheduled maintenance within established metrics. Drove repair cycle from 84 hours to 66 hours.

Led team safety engagement that resulted in achieving 1 year injury free.

Sponsored Lean AWO to develop standard work for Locomotive Overhauls to meet metric of 180 cycle hours and 180 labor hours.

Quality Leader 2010 – 2011

Responsible for Locomotive Quality/Reliability out of the Union Pacific Locomotive Repair Facility in South Morrill Nebraska.

Analyzed locomotive failure/repeater data for trends. Worked with local team to drive improvements resulting in a 6% reduction in 14 day repeat shopping’s.

Worked with Fleet management to develop work scope changes, Modification implementation plan and validation to improve reliability/quality.

PROFESSIONAL EXPERIENCE

Cytec Industries – Stamford CT

Maintenance Manager – Willow Island WV 2004 – 2008

Maintenance & Utilities (including Waste Water Treatment) leader with accountability for maintenance reliability, process improvements and reduction of maintenance costs and improved efficiencies for this Chemical operation which employs 250 people.

Managed first total plant outage in six years which was completed on time and with no safety incidents. Work included overhaul of electrical, well water and production equipment.

Lead implementation of new planning and scheduling process to more effectively utilize resources and improve maintenance and repair metrics for production departments. This resulted in a reduction average time per job by 30%.

Directed planning team to begin process of building job plans for efficiencies in repetitive work. This process increased job plan bank by 30% and improved planning metrics.

Oversight of 7mm Capital budget.

PROFESSIONAL EXPERIENCE

General Electric Co –Fairfield, Conn

G.E. Aircraft Engines – Arkansas City KS 1984 - 2000

Held numerous roles to include Quality Control, Production Control, Supervisor, Propulsion Engineer and Operations Leader.

Developed training plan for Mechanics/Inspectors in Final Engine assembly area.

Completed Six Sigma Green Belt Certification.

Worked with Product Support Engineering to assess component failures, revise inspection criteria and develop/implement repair methods.

EDUCATION

West Virginia University, Parkersburg WV, 2008

Bachelors – Applied Technology

TRAINING AND CERTIFICATIONS

Six Sigma Green Belt Certification.

Military Experience

USAF – 1978 to 1984

Hobbies/Interests

I enjoy time with family, playing golf, old cars and recently have become interested in RC Airplanes.

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