Manager Lean Manufacturing
Resume:
DAVID R. SHEEHAN
Torrance, California 90501
310-***-**** (Cell)
***************@*****.***
SUMMARY
Seasoned leader and independent contractor with 19 years experience in Lean Manufacturing and Supply Chain Management. Particular strengths include continuous improvement, capacity management and planning, standardized workplace measurement and flexible design, as well as process engineering and implementation. Significant industry experience in food processing, metal working, automotive, packaged goods and distribution.
WORK EXPERIENCE
SOLE PROPRIETOR, Operations Consulting, 2008 to Current
Sold, managed, and delivered consulting services to a diverse collection of clients from multiple industries and disciplines. My work has enabled client companies to realize cost savings and valuation improvements exceeding fees by a ratio of well over 10 to 1. Some client project highlights include:
Weyerhaeuser, redesigned building materials distribution operations resulting in a 40% reduction of acreage requirements during a period of increased sales. The client company established new all-time production records within the first week of implementation. The project included a thorough assessment of the operation, training of all hourly and salaried staff in the principles of the Toyota Production System (Lean), design of future state condition, pilot run verification and launch support. This project was deemed so successful; Weyerhaeuser expanded these methods to their entire North American network.
Foster Dairy Farms, completely overhauled transportation network resulting in a reduction of tractor/trailer/driver combinations from 81 sets to 64. This represented a reduction of transportation costs of 32% or about $3.9 million annually. This cost reduction was accomplished while improving on-time performance and delivery frequency to the retail stores. Using proprietary scheduling algorithms, I was able to complete this study and implementation in less than one month.
Fox Racing Shocks, utilizing continuous process flow and TQM techniques increased the output of their shock absorber production lines by 25% in less than six weeks. The client expanded their World Class Manufacturing effort to include their power sports production line as an outcome of the successful execution.
Attends Products, (formerly PaperPak), my projects included rapid changeovers of machinery, training of work force in lean techniques (TPS), installation of a customer-driven “kanban” scheduling system, product rationalization, manpower time studies as well as inbound material flow improvements.
Nancy’s Foods, (purchased by Heinz), led rapid changeover project and redesigned scheduling process resulting in a capital project avoidance of over $2.5 million (expansion of their frozen storage warehouse). Customer lead times were reduced from over two weeks to less than four days as a result.
Aware Products, (cosmetics manufacturer), revised chemical mixing operation to enable a redesign of the production control processes resulting in 40% capacity utilization increase and reduction of customer lead times. These actions freed enough capital to expand business without the use of borrowed funds.
Polypak USA, (plastic films manufacturer), led change management effort improving capacity utilization to turn an annual loss to a profit within six months. My actions resulted in the ability for the client to avoid bankruptcy, plant closure and outsourcing as stated by the client CFO.
Ameron, (steel fabrication for large scale construction), redesigned product flow and production lines reducing lead times by more than 55% and reducing yard storage needs by a factor of 3. This eliminated the need for purchase of additional expensive bridge crane and saved the client several million dollars annually.
Confidential Clients, include furniture manufacturer (eliminated entire building and 2nd shift operation through use of ‘cellular manufacturing’ concept), Asian automotive manufacturer (reduction of mis-allocated vehicles), German automaker’s service parts inventory control (improved picking efficiency and warehouse management), consumer packaged goods manufacturer (production control revamp), plastics molding company (redesigned production lines, approx. 40% improvement) and health foods distribution company ($600k cost reductions).
TOYOTA MOTOR CORPORATION, Multiple Locations, 1996 to 2007
Promoted six times to various functions uniquely combining the skills and experience of manufacturing, logistics management, business reengineering, project management and training. Positions held:
Consultant-Toyota Consulting Group, Torrance, CA
Original partner of the Toyota Consulting Group a business unit within Toyota dedicated to implementing the Genuine Toyota Production System in non-automotive companies. Process improvements and use of best practices allowed clients to experience typical productivity improvements of 20%.
Process Manager-Vehicle Distribution, Torrance, CA
One of four team members selected to redesign Toyota’s vehicle distribution system. The new process reduced total order-to-delivery-time by thirty days from ninety. This improvement dramatically improved market responsiveness, aided product launch and reduced costs by an estimated $240 million.
Manager-Logistics Administration, Torrance, CA
Led the transportation claims subrogation process. This operation encompassed claims processing, dealer payments, collections from carriers and dispute arbitration. Application of TPS (Lean Manufacturing) principles resulted in a 25% reduction of labor requirements for the department.
Strategic Planner-Logistics, Torrance, CA
Created strategic planning studies driving improvements in the Toyota vehicle distribution network. These studies included: facility rationalization, financial analysis, production planning, vehicle marketability impacts and labor contractual issues. Engineered vehicle routing changes resulting in planned savings exceeding $10 million annually. Negotiated rate agreements with major railroads and trucking companies.
Production Manager, Fremont, CA
Directed all production activities for two shift operation including: accessory installation, railcar loading, data processing, maintenance, operational budget and quality assurance. Hired and trained four department supervisors and over 60 hourly production employees. Implemented ergonomics procedures that resulted in winning Toyota’s national safety award twice. Lowered costs enabling the Fremont operation to achieve over $7 million profit. (11% of sales) Exceeded 100% efficiency levels for every month of operation.
Process Engineer, Newark, NJ
Designed and delivered training curriculum highlighting lean manufacturing tools such as 5S, heijunka capacity planning, kaizen, kanban, vendor management, master scheduling, etc. Successfully led “JIT” factory floor redesign reducing cycle and procurement time from six hours to less than one. Improved quality control levels by 20%.
Senior Supervisor, Georgetown, KY
Hired, trained and assisted in the formation of a greenfield vehicle distribution facility shipping in excess of 250,000 vehicles annually. Invented and executed the concept of night rail loading operations reducing acreage requirements by 50%. This creation remains the industry standard to this day.
GENERAL MOTORS CORPORATION, Danville, IL, 1994 to 1995
Held positions of supervisor, labor relations representative and pre-production engineer. Skills acquired include: Leadership in a combative labor environment, collective bargaining and administration, health and safety, tooling engineering, pattern making, machining, casting, heat treating, bill of materials auditing and capital budgeting.
EDUCATION AND PERSONAL
CARLETON COLLEGE, Northfield, MN, Bachelor of Arts, Economics. Member of U.S. Olympic Wrestling team (alternate), Avid cyclist, Six Sigma Black Belt trained, Lean Certified, Basic conversational ability in Spanish and Japanese, Proficient user of Word, Excel, Power Point, Visio, Outlook, and Access. Distribution Management Association, former member of the board.
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