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
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
EDUCATION & TRAINING
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