Project Management Six Sigma
Resume:
Chip LaPole
Continuos Improvement Manager–
Lean Six Sigma, Automation, Robotics,
Process & Cost Optimization
Newton, KS 67114
***********@*****.***
Versatile and results driven Project Management Professional with demonstrated Engineering aptitude and with Lean Six Sigma applications. Numerous experience citations and a commitment to achieving excellence. Proven experience in the following areas:
•Automated ADTA Sorting Systems for AMAZON
•Robotics, AGV’s (LIDAR Logic Protocol)
•Ag & Industrial Vehicles, HVAC, Refrigeration, Medical Equipment, Amazon Distribution Centers
•DOD: Submursable Valves Flap Actuators & Landing Gear
•Build to Stock and Build to Order Environment
•Machining, Fabrication, Welding and Assembly
•Injection, Rotational and Blow Molding
•Industrial Coatings, Liquid, Powder and E-Coat
•Experience in MIS with SAP, ERP, MRP, EDI and WMS
PLM, PDP, DFMEA, PFMEA, PPA, QMS
•MS Project Expertise / Other Microsoft Tools
Experience in manufacturing and distribution which includes Amazon Fulfillment Centers. Agricultural Tractors, Combines, Construction Equipment, Refrigeration, Hydraulics, Electrical Components and Medical Products. Extensive experience in Process Optimization, Design Cost Analysis, Lean Manufacturing, Value-Stream Optimization, Kaizen, Kanban, Line Analysis, Factory Optimization, EDI and Barcode.
Effectively managed the planning, execution, assembly and launch of a total (6) ADTA “Automatic Divert to Aisle System(s)” in 3rd quarter 2023 - 2nd Quarter 2024. The 1st two for AMAZON’s new DVB5 Distribution Center in Pembroke Park (Ft. Lauderdale) Fla. Chosen to manage the launch of (4) additional system builds which included Amazon DOM2 (Omaha, NE for 2 ADTA systems) and (2) Systems for Amazon DLI8 in St. Louis, MO.
Successfully managed $22.5M capital budget for new product introduction and facility construction to manufacture John Deere’s 5105/5205 Tractor. Won Modern Material Handling Magazine’s “Productivity Excellence Award” for outstanding achievement in Lean Six Sigma and Quality initiatives.
Led International Challenger Tractor NPI Team through Design Cost Analysis and Optimization, as well as managed capital budget in implementing AGCO Challenger Tractor Facility. Delivered project on time and 7% under budget. Attained 97% on time delivery, reducing assembly work content 31%. Led international team of Purchasing, Operations and Engineering Professionals through the prototype and pilot builds of the IDEAL Combine Harvester. I was responsible for all global quality related issues and my team consisted of (71) dotted line reports around the globe. This agricultural combine set the record for lowest incidence of field failures of any product released by AGCO Corp in its history.
Managed Katecho new product introduction of “injectable assembly system” sold to Pfizer through PDP/PLM, system design, implementation planning and installation. This $3.1M robotic manufacturing system for high volume automated manufacture of injectables and design which was later utilized and reproduced to supply COVID-!9 Injectables.
Education: 1982 Bachelor of Industrial Technology - University of Northern Iowa, Cedar Falls, IA. Training and Specialization: Project Management, 2002 PMP & 2013 Project Success Method with MS Project (PMI Institute) and Lean Manufacturing (JCIT Institute-1997) & University of KY-2001 trained in Lean Six Sigma (Black Belt) while with John Deere & SAP User Training in 2001, ASAP in 2011. Currently enrolled in Six Sigma Global Institute Blackbelt refresher and Scrum Master Certification courses.
Employment History and Training in Chronological Order:
Automation Manager - Field Operations (Traveling)
Fort Lauderdale, Fla / St. Louis MO, Omaha, NE
AMAZON - Contracted by Entegee for BlueCrest Inc.
August 2023 - Present
Responsible for managing field staff of Electrical Engineers, Programmers, Mechanical Engineers and Electro-Mechanical Assemblers to complete machine build assignments. I have been specifically involved in managing AMAZON’s ADTA equipment builds at AMAZON’s various distribution centers throughout the USA.
Project Manager – Traveling
Muskogee, OK / Green Bay, WI
GPA Inc - Cincinnati, Ohio
Oct 2022 – Dec 2022 (Contract)
Responsible for assisting in the development of high-level master plan to transition (2) Georgia Pacific Paper Mill Facilities from manual material movement to “near” totally automated facilities. Project included feasibility studies, equipment quotations, automation quotations, load/unload station design and development, demand planning, throughput analysis, identification of capacity constraints, manpower reductions, manpower redeployment, interfaces to existing equipment, new system requirements, fixtures and tooling, vision systems, limit sensing, load sensing, multi-positional lift tables, physical layout, supplier recommendations, cost analysis, capital budget development and capital requests.
Deliverables included MS Project Plan with tasks, timing resources and hours required as well as assisting in meeting with GP upper management to keep them informed of critical path, shutdowns and startup dates.
Project Manager
Chance Rides - Wichita, KS
May 2022 – Oct 2022 (Contract)
Responsible for identifying, leading, and executing key projects and programs in alignment with capital budget and business objectives / KPI’s. The focus of this role is on continuous improvement, cost reduction and the attainment of profitability goals through the implementation of Lean Manufacturing methodology and technological improvements.
Efforts focused on Value Stream Mapping and optimizing overall “Order to Delivery Process”. This includes “Sales Order Definition” to Engineering for Design, Bom Release, Purchasing and all aspects of information flow. Build Order Fulfillment then executed by Manufacturing through Final Assembly and delivery of finished goods to the customer.
Quality & Continuous Improvement Manager
Kubota Great Plains, Abilene, KS - Construction Equipment Division
August 2020 - April 2022 (Contract)
Responsible for staff of (11) Quality Engineering Professionals supporting “SCL new product launch” and industrial/agricultural attachments. Developed and implemented quality plans and procedures for new and existing products. Areas of Responsibility: Fabrication, Weld, Paint, Assembly, Precision Measurement (CMM), Warehouse Management System & PPC (Purchase Part Certification), Shipping & Receiving Inspection, Project Management which included assisting in deployment of AGV system and Parts Warehouse Order Deployment (Picked Parts and Inspected orders to Assembly)
Responsibilities:
•Supervised and Trained Quality Staff of Eleven (Hired 6 additional inspectors)
•Identified and resolved Quality Issues by leading Cross-Functional Teams for problem resolution
•Drove Continuous Quality Improvements, Best Practices and Lean Six Sigma implementation...
•Systematically reduced Scrap and Rework as well as “DOVE” Quality vision
Personal Leave of Absence (Family Illness & Mother’s Death)
April 2019 – July 2020
Mother became ill with dementia and provided care for her through in home Hospice until she passed on April 14, 2020.
Project MANAGER - IDEAL Combines (Extended Contract)
AGCO CORP. Hesston KS (Agricultural Equipment)
May 2016 – April 2019
Effectively supporting NPI, Global Engineering and Quality Optimization for IDEAL Combines in Europe, SA, Australia & US. Attaining excellence through timely, value-added results in the following areas:
Leadership Role – Provided work direction for IDEAL NPI Team through product release.
Leadership Role – Manager of Global War Room Operations (NPI, Engineering, Quality and RF)
Leadership Role – Implementation of APEX Global Engineering & Supplier Quality Excellence
oSystem Design, Data Migration, Data Cleansing, PPAP Approvals, Deviations,
Team Support Role - Supplier Validations (Capability Studies and Statistical Performance)
Team Support Role - Tooling Validations (Runoffs and Optimizations)
PROJECT MANAGER - PMO CI Team (Contract)
ACIETA LLC, Council Bluffs, IA
Feb 2015 – April 2016
Responsible for planning, directing, and implementing complex industrial automation projects, on time and within capital budget parameters. Effectively coordinated technical information sharing between Acieta and the customer. Consistently supported Sales and Marketing teams in preparing proposals and quotes.
Responsibilities:
Primary interface between customer and Acieta
Provided dynamic and results oriented project team leadership
Effectively developed and managed project, implementation plans and staffing
Managed financials (CAPEX, OPEX and GP)
Automation applications included the following areas:
Material Handling, Kitting, Machining, Assembly and Welding
Industrial Coating Application and Sealant Dispensing
Customer references and experience citations (available upon request): Honda Corporation (Timmonsville, SC), General Grind (Aledo, Illinois), Hydro-Gear (Sullivan, Illinois), Curries Company (Mason City, Iowa)
Engineering Manager – Product Cost Optimization
AGCO CORP, Jackson, MN (Agricultural Tractors – Challenger, RoGator, TerraGator) (Direct Hire)
June 2012 – Feb 2015
Directed (2) cross–functional teams:
Product Cost Optimization (PCO) Team – Continuous improvement of existing (released) products in field
Design Cost Analysis (DCA) Team – Cost reduction/cost roll-ups for new vehicle design releases.
Led AGCO Product Cost Teams to realize $1.5M implemented cost savings in 2014 and $2.6M savings in 2015. Effectively supervised staff of experts in engineering, manufacturing, purchasing and logistics:
Sr. Project Manager – Equipment DESIGN AND Plant Engineering
KATECHO INC. Des Moines, IA (Direct Hire)
Feb 2011- May 2012
Managed Equipment Engineering and Plant Engineering organizations, responsible for supporting custom medical equipment design, manufacturing, maintenance, and assembly; in addition to major capital projects and new
product launch:
Managed $3.5M annual budget for equipment acquisition, productivity improvements and Facility upgrades
Implemented robotic assembly system utilizing (9) Denso (5) axis robots in conjunction with Flex-Link conveyor system and PLC controls, for the application of hydrogel and assembly of electrode vest components. This project was a capital investment of $1.2M with a payback under (2) years.
Implemented sequenced and paced assembly line utilizing Flex-Link conveyor, Schmidt presses and UV curing to produce electrode assemblies. This project represents a capital investment of $375,000.
Directly supervised engineering professionals, maintenance technicians and shop floor support.
Managed total of (11) direct reports which included Product and Plant Engineering Teams.
Project Manager of Logistics CI (Contract)
RYDER LOGISTICS, Waterloo, IA
Jan 2010 – Jan 2011
Optimized distribution and storage practices and procedures for John Deere components managed by Ryder.
Effectively implemented Lean Manufacturing principles to achieve balance between manufacturing and assembly demand, as well as implementing rite sized Kanban containerization and logistics improvements.
Defined material replenishment procedures, methods, and quantities, in addition to optimizing conveyance systems and triggering min/max quantities for high velocity parts.
Engineering Project Manager (Contract)
CHAMILIA CORPORATION, Minneapolis, MN
Nov 2009 – Dec 2009
Optimized order fulfillment through Warehouse Management “System” to support global distribution of product.
•Eliminated nonvalue added work content through accurate Value Stream documentation and optimization.
•Defined barcode requirements, format and developed “custom/intelligent” SKU “expanded” nomenclature.
•Implemented GS1 UPC-A barcode format for all global product offerings and enabled barcode scanning which included equipment definition, CER, and implementation.
PROJECT MANAGER - CONTINUOUS IMPROVEMENT
MCQUAY INTERNATIONAL, Faribault, MN (Direct Hire)
July 2007 – Oct 2009
Implemented timely and effective continuous improvement initiatives, best practices, Lean/Six Sigma, quality improvements and capital projects. Developed and managed capital appropriations and capital budgets.
•Effectively developed and utilized Process Flow Diagrams and Value Stream Maps. Identified non-value-added work content (walking, sharing tools, wait time, change over, etc.) and optimized sequence of work. Optimized process flow and level loaded machine tools to minimize down time and maximize throughput.
•Developed effective work instructions and led training which resulted in fewer defects, reduced process cycle time, increased throughput, line balance and On-Time Delivery.
Project Manager
CASE NEW HOLLAND, Burlington, IA (Contract)
Nov 2006 – June 2007
Coordinated Burlington, IA design teams and the Calhoun, GA order fulfillment team activities in DFM. Led cross–functional teams utilizing DFMEA and PFMEA methodologies. Defined process flow, initiated design changes and cost savings opportunities. Defined value stream, layout, logistics, Kanban sizes, replenishment rules/procedures.
•Developed and managed effective and timely Microsoft Project “Master” plan for new product release
•Implemented Lean Six Sigma for dozer assembly resulting in a 39% order to delivery lead time reduction and a cost savings of $255,000, which included direct labor, rework, and inventory savings. Implemented kanban, 5S, line balance, supplier milk runs, flex scheduling and an inventory supermarket.
Sr. Engineer
Carrier Corporation, McMinnville, TN
Nov 2003 – Oct 2006
Effectively defined and sustained the equipment and tooling required for the machining, fabrication and welding of component parts for assembly of industrial and commercial HVAC units.
Effectively participated in strategic sourcing decisions.
Effectively led procurement decisions (Make vs. Buy)
Led DFMEA / PFMEA executions.
Prepared Dashboards with P/N, where used, cost breakdown, lead time, OTD in house/outsource
JOHN DEERE, Multiple Business Units,
Jun 1998 – Sept 2003 (Direct Hire)
During this time, I worked for the following business units in the capacities described below:
•Sr. Assembly Engineer – Construction Equipment Division in Davenport, Iowa
oDynamically led Davenport Cab Factory Lean Manufacturing implementation
$3.75M capital project $1.2M annual savings completed on time and under budget
125K sq ft focused factory, Lean Manufacturing with innovative use of proven technology
•Assembly Supervisor – John Deere Power Systems in Coffeyville, KS
o200 units behind schedule when I came on board and led them to current in 11 months
Implemented Lean Manufacturing and “good parts in the right place at the right time”
•Project Manager (5000 Series Assembly Facility) – John Deere in Augusta, GA
o$22.5M capital investment completed on time and under budget.
o225K sq. ft. factory, producing 90 tractors of exceptional quality, on time; every day
Engineering Operations Manager – Finishing (Coatings), Electrical, Injection Mold & Final Assy
E-Z-Go Textron May 1993 – April 1998 (Direct Hire)
Assembly Engineering Manager
S&C Electric May 1991 - April 1993 (Direct Hire)
Project / Program Manager
Ingersoll Corporation (Engineering Consulting)
July 1988 – April 1991 (Direct Hire)
Major contributor to South America’s project team in support of Caterpillar Corporation’s expansion projects from Sao ’Paulo Brazil to Piracicaba. In this role I focused on manufacturing, logistics and layout implementing Lean Manufacturing methods, 5S, Demand Planning, Milk Run Part Deliveries, Kanban, Kaizen and overall, Six Sigma methodologies. I contributed to HR demographics analysis and development of factory manpower, professional and contract staffing requirements.
PROFESSIONAL AFFILIATIONS: AMA, SME PMI
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