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Manager Lean

Orlando, FL
February 23, 2020

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Byron Burns

*** ****** ***** ** ******, Oh ***** Phone: 260-***-**** Email:


Master Black Belt “Lean” Certification (DMAIC)

*-*, ***, ***, ***, TPM, Focused Factory, SMED, VC, Production Smoothing

MDI, PDM, Kanban, 3-P, Jidoka, Model Cell, VSM (business and shopfloor)

Shop floor Kaizen, SPC and Poke Yoke, Business Process, RPA, Lean Quest

Value Engineering/Analysis Certified Training

Experienced in Several Management Functions to include; Lean, Six Sigma, Operations, Quality, Safety, Procurement and Production

Experienced Quality Manager Experience; Familiar with and responsible for; Automotive Core Tools, PPAP requirements, APQP process, FEMA, Control Plans, Product verification, etc., ISO 9001 2015 (successful audit), IATF 16949 (internal and external audits) and Tier Two Supplier Development Process,

Developing and Maintaining Quality Systems. Responsible for Internal and External Audits, Project Launches, Customer Satisfaction, KPI, and customer relations.

Responsible for Quality Inspectors and Quality Engineers, dedicated for customer focused, i.e. Ford, Nissan, Honda, Chrysler and GM

Experienced Lean Manager with over 22 years of Lean Management and Policy Deployment

16 years working for a Tier 1 Automotive Supplier

Experienced in conducting ALL aspects of lean training and projects, facilitating over 250+ major Kaizen events and 300+ minor Kaizen events

Shingijutsu Gemba Training (Japan Gemba Kaizen Experience)

Strong Lean, Kaizen, Continuous Improvement and Toyota Production Systems (TPS) knowledge

Experienced in utilizing brainstorming, problem-solving, standard work, set up reduction, cycle time analysis, 5S, Visual Management and Error-Proofing methodologies

Experienced as a self-employed Lean Consultant

(Contracted by ASV/AIP to implement Lean and Model Cell Concepts at two of the new acquisitions. One in Clinton TN and the other in Springfield MO. Developed 17 “Model Cell” within 18 weeks of continued lean events. Launched their first lean activities at both locations)

Value Stream Mapping / Root Cause Analysis leader

Experienced developing AIAG: Control Plans, PFMEA, DFEMA, Process Flow etc.

Mentored Lean Coordinators and Lean Techs

Certified associates


AURIA Solutions, CI Manager Mar 2019 – June 2019 (Downsizing)

Responsible for lean activities and measureables.

Participated and Facilitation of three CI project

MTD (Manchester Tool and Die), Lean Manager June 2017 – Mar 2019

The owner of Manchester Metals Inc. left and started work at MTD. Same Manager from Manchester Metals Inc.

Responsible for all Lean activities in the Tool Shop, developing annualized metrics never used before

Developed MTD’s first PDM annual plan, with a three and five-year plan - first “LEAN” training

Develop and Track KPI, never had before.

Responsible for developing OTD, Scrap, Customer Satisfaction and Cost Analysis

Manchester Metals Inc., Lean Manager/Operations Manager Sep 2014 – June 2017

Responsible for all Lean activities in the Foundry and Annual Safety and Health Gap Analysis Certifications, which improved each year

Responsible as the Manufacturing Operations Manager and Lean Manager. Developed their first PDM annual plan, first “LEAN” training ever, and Standard Work and Shipping accuracy.

BLB Lean Consulting LLC, Owner - Self-employed as a Lean Consultant Mar 2014 – Sep 2014

Contracted by ASV/AIP to implement Lean and Model Cell Concepts at two of the new acquisitions: One in Clinton TN and the other in Springfield MO. Developed 17 “Model Cell” within 18 weeks of continued lean events. Launched their first lean activities at both locations.

ASV /AIP Wheeled Coach, Fleetwood RV, Lean Op Ex Manager and Procurement Manager July 2008 – July 2013

Started Lean certification program January 2009 and certified 108 associates by July of 2012, 75% in first year

oFacilitated bi-weekly training on all Lean material for continuous training of all associates and a monthly Major Kaizen Event to develop a Lean culture

oAssisted / directed corporate Lean Managers. Developed the new ASV/AIP corporate training material for Lean

oDeveloped the Bronze and Silver Lean Certification Program

oTracked and recorded all minor kaizen activities and developed the award system for minor projects. Some months in the range of eighty to one hundred were recorded

Worked with engineering, sales and production on new product developments (APQP) - met monthly

oLaunched and tracked APQP process - The Van Line Value Stream move in particular went from 1.75 units per day to 4 units per day within a 2-week time frame - Van Line Cabinet Assembly Cell Development, Line Side - Road Rescue factory moved from batch to one-piece flow from South Carolina to Florida

Tracked all inventory levels and inventory turns including chassis and developed supplier development program

oTracked and ordered aluminum ingots forward buys ($250.00 per unit savings one year)

Hoshin Kanri Strategic Training, Policy Deployment. Developed a 5 year plan and achieved it in 3 years.

Tracked Continuous Improvement activities and savings in Purchasing and Lean Manufacturing

Trained and developed a Steering Committee to direct and guide the Lean process to meet the company goals

Tracked and reported monthly metrics internally and at the corporate level

Freudenberg NOK, Lean and Quality Manager (Ligonier IN, Shelbyville IN, Bensenville IL.) July 1992 – July 2008

Responsible for all technical aspects of Lean for the Automotive Tier One Supplier of rubber molding and CNC machine production products, including:

Value Stream Mapping and Team Development

Standard Lean Training Modules and Manufacturing Improvement Processes

Continuous Improvement Project Teams

Cellular manufacturing development (one piece flow)

Hoshin Kanri Strategic Training, and develop and track Monthly KPI

Supplier logistical projects ; supplier sourcing projects ; Impacts of Inventory management

Business Process Kaizen and Mapping

Quest Organization and Training

Business Process Improvements, supplier Development processes

5-S ; Production Preparation Process (3-P) ; Set-up Reductions ; Productivity Improvement

Model Cell Concepts with Gemba Boards for tracking daily process and Root Cause Analysis

Trained and led all the manufacturing associates to promote continuous improvement on a daily basis

oUsed FROKA (Financial Results of Kaizen Activities) to document all savings. Results amounted to an average of $1M in savings y/y from 2003-2008 totalling to $5M in Hard/$2M in Soft savings.

oDirected, organized and facilitated all major (over 400 majors) and minor Kaizen events with lean tracking metric

oResponsible for training and certifying Lean Systems Green and Black Belt candidates

oConducted several Executive Overview Training modules with suppliers and customers using Lean principles

oDeveloped and maintained an active Lean Steering Committee to include all staff members and production associates in selecting the projects that supported corporate goals

Prepared and achieved the Shingo Award (Award for Manufacturing Excellence) in our VCT facility and was Recognized for the VNA location

Active with Honda Trouble Shooting Team and OEE Implementation for eighteen months as the acting Quality Manager, till replacement was hired.

Developed ISO/TS/IATF16949 quality system through Lean business process and lead on audits

Saved the Freudenberg NOK over $5M in hard savings and $2M in soft savings

Project Manager a new supplier launch and development a new bushing program for a new Honda product line

Global Gemba Certifications at 2 FNGP locations


Business Courses (Ivy Tech. Fort Wayne, IN)

Freedom Academy Business and CAD Courses

Six Sigma Green Belt Certification

Six Sigma Master Black Belt Certification - Freudenberg and re-cert at Wheeled Coach

Master Black Belt “Lean” Certification (2 years program completed)

o5-S, SWI, OPF, OEE, TPM, Focused Factory, SMED, VC, Production Smoothing

oMDI, PDM, Kan Ban, 3-P, Jidoka, Model Cell, VSM (business and shopfloor)

oShop floor Kaizen, SPC and Poke Yoke, Business Process, RPA, Lean Quest

oValue Engineering/Analysis Certified Training

Develop and Train on Control Plans, PFMEA, DFEMA, Process Flow etc.

Proficient with JDE, MRP, QAD, Mapics, Epicor and others

Training and tracking OEE

Shingijutsu Gemba Training (Japan Gemba Kaizen Experience)

ISO, TS and IATF 16949 Quality Systems Development and Internal Auditor Training

Proficient with Microsoft Office, Excel, Power Point, Word, Mapics, QAD, QSI

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