Continuous Improvement Inventory Management

Jeffrey J Butler

***************@*****.***, 224-***-****

SUMMARY

Quality-driven Production professional with 20+ years of Supervisory/Management experience in Assembly and Manufacturing with the ability to lead others and provide continuous improvement opportunities in Safety, Quality and Productivity.

SKILLS & PROFICIENCIES

Team Development

Production Scheduling

Developing Process Instructions

Navision and Mapics ERP systems

Performance appraisals

Quality Systems

Microsoft Office

Inventory Management

In-Lining, Plant Flow

ISO

PROFESSIONAL EXPERIENCE

SWB INC, 529 Capital Dr. Lake Zurich IL. 60047 8/15/2023 – 12/22/2024

SWB is a privately owned business which supplied machined components, sheet metal fabrications and secondary operations to end users in NE IL.

Daily Route - Planned and executed a daily pick up route from a multitude of partners in the Chicago/Rockford area(s). These schedules were determined by On Time Delivery requirements for our end users and factoring in any secondary operations that maybe required which factored in lead – times provided by the secondary partners.

Inspection and packaging – Returned all parts to SWB where I performed inspection of all parts, reported any non-conformities and worked with the owner and suppliers to have the product re-worked. When components passed inspection I packaged them according to specific shipping requirements developed by SWB and certified by the end users. The packaged parts were then staged in date specific racks for timely delivery when required.

Delivery – Planned and distributed parts in a sequence that would factor in all partner operational needs such as unmanned dock periods, COB, and specific times requested by end users, The complexity of line down issues due to timely ordering or for parts that needed rework or replacement would routinely have an impact on scheduled route.

SELF EMPLOYED 11/22 – 7/23

Purchased and rehabbed (2) single family homes in the Schaumburg area. Hired and schedule all required contractors. Working with my partners completed all of the tear down and a majority of the rehab.

Inter – Continental Trading USA Inc. 3/1/2021 – 10/15/2021

Inter – Continental packaged and did regional distribution of tobacco products and accessories.

On a daily basis determined brand and quantities of the product(s) to be packaged and assigned the labor requirements to accomplish daily production schedule’s

Completed daily production reports which communicated consumption of products used (LBS), any associated downtime as well as any fall – out (waste). These reports were then combined to create monthly reports that were used to satisfy the FDA requirement for usage as tobacco is very highly regulated.

Worked with suppliers to schedule releases for tobacco, branding packaging as well as corrugated requirements.

Performed monthly inventory of all products.

Balanced daily shipping reports against inventory depletion.

Diemasters Manufacturing, 2100 Touhy Ave, Elk Grove Village, IL 2/1/2021-12/1/2021

Diemasters is a division of Weiss-Aug Co, Inc. Diemasters is a stamping house that supplies stampings and value added assemblies to end users such as Ford Motor Co, Honda and Briggs and Stratton.

Assembly Supervisor, 2/2/2021-12/1/2021. In this position I was responsible for the daily activities of the automated and manual assembly teams.

Customer Focus – Ensured all assemblers completed in-process inspection reports and validated that the results were accurate and within specification.

Productivity – Set monthly production schedules and reported daily production numbers with the management team to include specific reasoning for any shortfalls. Established valid production rates by completing comprehensive studies of each assembly line. Worked with the Engineering and Maintenance teams to correct/improve processes.

Internal work flow - Worked with the stamping, procurement and outside process managers with deliverables to plan schedules accordingly.

BUEHLER @ DIVISION OF ITW, 41 WAUKEGAN RD. LAKE BLUFF, IL. 60044 11/7/2007-2/7/2020

Buehler is a division of ITW supporting the Manufacturing, Laboratory, and Academic communities with destructive testing and measuring equipment.

Assembly Supervisor/Quality Supervisor (4/2012), 11/1/2008 – 2/7/2020. In this position I was responsible for the day-to-day operation of the department to include Safety, Quality, and production levels. I worked with all supporting departments and was effectively able to improve metrics in each area.

Employee Moral/Improved engagement – I put into place “Self Directed” Work Teams. This process allowed for the teams to meet independently or with representatives of other functions as needed. Each team member was assigned to a role within the team (Team leader, Safety Rep, Quality Rep, Scribe, etc.). This process provided the feeling of empowerment and allowed for more immediate resolution for critical issues.

Line Efficiency/Reduced Assembly Times – Developed line layouts (in-lines) on existing products that improved productivity and performance. Using strategies such as sub-assemblies, out-sourcing point of use and layout, reconfiguration of all legacy production lines to provide these efficiencies and used continuous improvement strategies to maintain them.

Safety/Injury Avoidance – Was a member of the safety committee throughout my Buehler tenure. I have extensive experience with root cause investigation and CA implementation. Created an inspection scorecard that tracked and measured departmental housekeeping performance with specific focus on safety. Reduced safety incidents over the last 3 years that included (2) near miss, (0) lost time and (0) recordable events.

NPD support - Worked with the NPD team to implement new products into the assembly department. Starting with the Beta builds we shadowed the design engineer(s) to establish manufacturing friendly methods for the assembly of the new products and also worked with the IE’s to put in place MWI’s that mimicked the agreed upon steps and formatted them in such a way that an experienced assembler with no exposure to the product would be able to follow and complete the product with the desired results. After these steps were completed I was responsible for putting the production line together. This would include all Safety Elements, Flow Racks, Inventory Locations, Kan-Ban, and Fixture Requirements.

Quality – Continuing my work with our China division and after making several trips to Shanghai to perform process audits and evaluate CA implementation; they are currently at 98% acceptance for initial quality.

Quality Technician, 11/7/2007 – 11/1/2008. In this position I was responsible for the incoming inspection of all products manufactured at our China division. I was also responsible for all Manufacturing floor quality related issue’s up to and including the RMA and Debit processes.

Incoming Product quality/Reduced inspection percentage – Initially doing 100% inspection on all incoming China equipment I was able to reduce the inspection criterion to 50% within 1 year. Documentation of all quality related issues and developing a functional CA system while working with our China division set focus on issues that were able to correct high volume incidents.

Quality rejects/Reduced inventory dollars – There was 100k in unprocessed quality rejects when I started which was reduced to WIP rejects and maintained through process changes. After clearing the entire backlog I wrote and maintained procedure’s that stipulated the actions required for effective disposition. I also worked with the Procurement department in developing supplier requirements to support our processes.

Floor rejects/Reduced rejections – Working with the assembly team at the point of use evaluated product performance and was able to identify and eliminate 25% of total supplier rejects due to incorrect performance evaluation.

INDUCTION HEAT TREATING CORPORATION, 775 TEK DR. CRYSTAL LAKE, IL. 60014 8/2003-7/2007

IHT is a small business comprised of 50 employees. They serviced all industries fulfilling their need of induction hardening and tempering of all types of steel and steel alloys.

Production Supervisor/Customer Service, In this position I was responsible for the scheduling of all jobs to the production floor and insuring all process step and quality documentation was being completed and accurate.

Scheduling Production Runs – This is a process that was reviewed daily due to the industry need for expedited services. This would require the need to understand the process capabilities of the equipment to move products around and the need to require OT in order to keep our promises with the customer.

Customer Service – Communicated with all customers on schedule and completion dates. Worked with them on expedite needs as well as any quality related issues.

Documentation – Insured that all product being returned after processing had all required quality documentation and sample pieces.

ITW BUILDEX, 1349 W. BRYN MAWR, ITASCA IL, 60143 4/1/1986-4/4/2003

Buildex is a division of ITW with 300 Employees supporting the Metal Building and distribution networks with self-drilling and tapping fasteners.

Plant Manager, 11/7/2001 – 4/20/2003. In this position I was responsible for all activities at our Metal Building facility. The facility had 56 machine operators and supporting staff. This facility manufactured between 15mm – 25mm fasteners on a monthly basis consuming 200,000lbs+ of steel wire and rod.

Productivity – Using the strategy of Market Rate of Demand with the support of Kan-Ban inventory management I was responsible for setting up target inventory levels with safety stock triggers. With these tools in place and doing quarterly review of these levels was able to keep MOH levels to < 1 month while being able to keep up with sales demand.

Safety – The manufacturing of fasteners is conducted in a very aggressive environment and safety programs/requirements need to be managed using continuous improvement philosophy. I set up a program where each of our (6) manufacturing teams within the facility competed using a monthly scorecard that calculated any near miss/recordable events, safety suggestions that were implemented, and weekly evaluation of the work area(s).

Procurement – I was responsible for all tools/supplies that were required in manufacturing. Set up a program with our tooling vendors to Kan-Ban the 20% of tools that were required for 80% of our production needs. Weekly reviews at our facility by the vendors would replenish target quantities from agreed upon safety stocks maintained by the vendors. Oil/coolants were updated to bulk delivery systems that dispensed right to the point of use. Supplier reps were responsible for maintaining inventory levels.

Quality/ISO – Maintained all elements of our ISO 9001 certificate. Worked with the quality manager to initiate root cause evaluation on quality events and was responsible for the process until corrective actions were identified and implemented. I also maintained the facility calibration program from meeting the required calibration frequencies to daily verification of required gages.

Production Supervisor, 6/1/1994 – 11/7/2001. In this position I was responsible for the day-to-day operations of the assembly department.

Productivity – I was responsible for the reporting of daily production numbers.

Quality/ISO – Responsible for ensuring required daily elements were being completed and that all supporting documentation was correct and in place.

Performance appraisals – Was responsible for writing and delivering quarterly reviews of progress towards goals and annual delivery of appraisals to the employee.

Group Leader/Machine Operator, 4/1/1986 – 6/1/1994. In this position I was responsible for the production and quality of fasteners I produced. I also supported other operators with troubleshooting needs and did the on-board training for new employees.

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