John E. Callery
Edmond, Oklahoma *****
[Operations & Quality Professional]
Results-oriented executive with a solid background within various functional areas in manufacturing, both domestic and foreign plant locations. Expertise includes Manufacturing Management, Production, Engineering, Supplier Quality, and Quality Control. Proven track record and strengths in achieving bottom-line results for safety, quality, growth, people development, profitability and increased efficiency. A multi-disciplined, hands-on leader offering outstanding leadership qualities, training and expertise.
Toyota Production System - Lean Manufacturing implementation s Automotive Production - Press, Body, Paint, Assembly & Powertrain s SPC s TQM s Six Sigma s Red X s PFMEA s VSM s APQP s PPAP s Continuous Improvement
sJD Power s NCBS s Warranty Improvement s QS-9000 s ISO-9001 s TS-16949 s ISO-14001 s Materials Management s Multi-Site s Plant Start-Up s Program Launch s Hoshin/Business Plan Deployment, Target Development and Sufficiency Planning s P&L s Operations s Quality/Supplier Quality Management s Multi-lingual s Productivity/Process Improvement
JEC Lean Solutions – Lean/CI Consultant 2014 – Present
Private Consultant providing expertise in the areas of TPS/ LEAN/Continuous Improvement as well as Hoshin/ Business Plan Deployment, Problem Solving, PPS, 8D, Red X, TPM/Equipment Effectiveness/SMED, Process Improvement, Standardization, Gemba / Visual Management, 5S, People Development, overall Change Management and Transformation.
ATC Drivetrain 2012 - 2014
Oklahoma City, OK
ATC Drivetrain remanufacture automatic transmissions for brands including Ford, Honda, Chrysler, GM, and more
Reported to the CEO with responsibility for manufacturing and overall P & L ($100M+)
Led (2) directors and (8) managers across two sites for transmission and engine production with over 700 indirect employees.
Managed Engineering, Maintenance, Operations and Safety.
Established Hoshin planning and performance measurement, overall EH & S program, Gemba / visual management, VSM activity and overall Lean transformation.
Established and led cross-functional teams to drive improved performance across all value streams.
All KPIs and metrics were improved to levels never achieved in the company previously - SAFETY performance (60% improvement – TRIR, DAWC), HPU / Productivity (24% improvement), OTD (88% to 97%), FPY(from 80% to 93%), EBITDA (19% increase), SCRAP(21% decrease).
Generated substantial improvements in the areas of engagement, morale and employee satisfaction.
CHRYSLER LLC– ASIA PACIFIC 2008 - 2012
Manufacturing & Operations Leader – Asia.
Responsible for all manufacturing and quality operations within the Asia Region – vehicle production facilities in Beijing, Fuzhou and Taiwan.
Also led the JV projects between Chrysler and Chery Automotive and Great Wall Motors in Baoding, China. Included (6) export programs for Chrysler, as well as overall teaching, coaching and driving Mfg. and Quality system / process improvements along with lean manufacturing best practices.
Established new business plans and strategies with the Chrysler Asia President for other business cases and new joint ventures throughout the region.
Key member of the Strategic Council Committee (SCC) reporting directly to the Asia Pacific CEO.
Overall P&L responsibility.
GENERAL MOTORS CHINA – SHANGHAI GM 2005 – 2008
Leader – China Operations.
Responsible for all aspects of manufacturing, supplier performance and quality improvement activities across all SGM and GM China Operations, which covers (6) Vehicle Assembly Plants and (2) Powertrain Manufacturing Facilities.
Overall areas of authority and responsibility for driving improvement activities within the Manufacturing, Supplier Quality and Product Engineering (PATAC) organizations and ensuring that global processes were followed.
Led implementation and improvement of GMAP processes – In-Process / Delivery Quality, GVDP / GPDP, Product Launch, CPIP process, J.D. Power improvement planning, warranty and reliablity / durability improvement.
Responsible for driving GM Global and AP Regional quality processes and initiatives throughout the SGM and SGMW operations.
Reduced warranty cost by 19 million USD.
GENERAL MOTORS THAILAND LTD., 2000 – 2005
(New plant operation)
Director of Quality & Product Engineering.
Responsible for all aspects of Quality, including; Quality Engineering, Inspection Operations, Quality Assurance, Supplier Quality, Aftersales Quality and new program development.
Product Engineering responsibilities including New program validation, engineering changes / revisions, vehicle development process, vehicle and part validation and COP / type approval for all programs – Opel Zafira, Subaru Traviq, Alfa Romeo 156, Isuzu I-190, Chevrolet C-190 and GMDAT (Daewoo) J-200. Launched all programs to timing, cost and quality targets.
Led the development of Red X / Shainin Problem – Solving for the Asia Pacific Region and established a team of over 60 certified engineers over a 2 year timeframe.
Outperformed all product home plant locations in the area of quality and warranty performance.
Developed a stellar local national staff including a Sr. Director and Director which allowed for no additional expat leaders in this position when I moved to another role in GM.
SHANGHAI GENERAL MOTORS CORP.LTD, 1997-2000
(New Plant Operation)
Director of Operations.
Established the Quality Organization for the largest joint-venture company in China (GM and SAIC).
Responsible for all aspects of Quality, including; Quality Engineering, Quality Planning, Inspection Operations, Quality Assurance, Supplier Quality and Powertrain Operations.
Integral part of SGM becoming the premier operation within General Motors.
GENERAL MOTORS DE MEXICO, 1994-1997
Planta Silao, Mexico
Director of Operations
Ensured reliability and efficiency of new plant operations
Advised for the manufacturing areas of Press, Body, Paint and General Assembly.
Hired, trained and directed a staff of 20 direct reports.
Was responsible for establishing and Managing Inspection Operations, Supplier Quality, Quality Engineer and Quality Assurance sections.
Successfully drove the Silao operation to becoming the top GM truck production facility in quality and productivity
Implemented Lean MFG and build-in quality processes.
Lead the plant safety committee
Developed the SGM project into the most profitable division within GM.
Toyota Motor MFG., U.S.A Georgetown, Kentucky 1986-1994
(New Plant Operation)
Assistant Manager of Quality Control
Managed quality operation and inspection for plastics, stamping, body and paint.
Oversaw assembly shops, product engineering, receiving/inspecting, raw material and audit lab areas.
Supervised and managed a staff of 288 personnel.
EDUCATION, TRAINING & PROFESSIONAL DEVELOPMENT
Bachelor of Science Degree - Chemical Engineering / Geology,
University of Kentucky
MBA -American Graduate School of International Management
Business Leadership Program – Thunderbird Executive Education
General Motors University – Finance College
University of Michigan Business School Executive Education
Strategic Planning and Implementation
Center for Creative Leadership - Brussels Belgium
Leadership Your Perspective
MBTI, CLI, BENCHMARKS, behavioral assessments
General Motors University (RenCen campus and online courses)
Over 150 hours of various courses…Leadership, Problem-Solving, etc. 1994 – 2007
General Motors Chairman's Honor Award - High Quality Launch of the Suburban / Tahoe / Yukon GM Mexico 1995
General Motors Chairman's Honor Award - High Quality Launch of Buick W Program. Shanghai GM 1998
Thailand Prime Minister's Industrial Award - Best overall Quality System among all Thailand manufacturing companies - GM Thailand 2004
General Motors Chairman's Honor Award - Successful Development of Chevrolet Zafira for Thai Domestic Market. GM Thailand – 2003
J.D. Power Gold Plant Award and "Best in Class" IQS Gold Award for 1992 Camry (Launch Manager)
American Society for Quality
Manager of Quality / Organizational Excellence Certifications – CMQ / OE
Society for Industry Leaders – Standard & Poor’s Vista Research
Industry Expert Consultant – Automotive Sector