Lean Accomplishments

• Reconfigure a food server cart product line manufacturer with “Lean Manufacturing” processes and techniques including Kanban, defined workstations and cells, systems for “pull through” production, flex manning, “Just-In-Time” techniques, and a revised facility layout.

• Plant re-arrangement for a 200,000 square foot facility to increase capacity, reduce cost and shorten cycle time for a major generator manufacturer. Included major process changes.

• Completed an evaluation and implementation of a new precision vise manufacturing line system with cells for about $2 million. Is a World Class operation. Included Request for Quotes and a variety of machine system concepts. Also initiated and assisted in the installation of a quick-change setup process for about 50 machines. Cross training and employee involvement.

• Evaluated electric motor electrical efficiencies regarding manufacturing practices and product design with cost variables for a major integral electric motor manufacturer.

• Completed five Appropriation Requests including Request For Quotes and quote matrix for a major manufacturer of motor generators.

• Evaluated varnish trickle and bondable wire applications and cost considerations for motor generators involving worldwide equipment suppliers.

• Evaluated Mexico manufacturing advantages and disadvantages with cost variables for one of the top electric motor manufacturers.

• Presenter of lean manufacturing papers at conferences.

• Evaluated a China electric motor manufacturer for a possible joint venture. Included a “green field” site facility evaluation with processes, equipment, and manning and production output.

• Benchmark Direct Current electric motor operations including an international facility.

• Conducted Value Analysis/Cost Reduction session for a worm gear manufacturer.

• Contributor to McGraw-Hill book, “Handbook Of Small Electrical Motors.”

• Provided manufacturing processes and product design practices for worm gear rolling.

• Evaluated the cost differences between bondable wire and varnish systems of electric motors for a major magnet wire producer.

• Benchmark electric motor fractional horsepower facilities, processes and operations.

• Assisted an electric motor component manufacturer in site selection in the Monterrey, Mexico area.

• Developed and conducted for the Small Motor and Motion Association a one and a half day class on “Motor Manufacturing 101.” Conducted for four years.

• Evaluated various assembly line techniques and processes for a fractional horsepower motor manufacturer.

• Project leader for a three-plant plant/production consolidation for a vise manufacturer.

• Developed manufacturing techniques, capital program, and manning for new type rail system for highway trailers.

• Plant consolidation for electronic component (stampings and automated assembly) manufacturer.

• Evaluated setup reduction program for electric motor lamination (stampings) manufacturer.

• Initial hiring screening process of technical professional candidates for a major Tier I automotive supplier.