Resume

Lean Your Way, LLC.
Lucas, Texas

CEO/Founder
2016 to 2019

Led The Oneida Group through a corporate Lean Transformation.

• The TOG achieved a 15:1 ROI through Super Kaizens.
• Increased productivity 3 fold and lowered overtime to 6% from 27%.

Led the closing and moving of a Plant for the Crosby Group in 90 days.

• Temporarily filled in as GM to lead the management team to complete the move under 90 days.
• Reduced the cost of running 2 plants by more than $350K a month during the transition. Won the Union over by engaging them to complete the move by improving safety, reducing absenteeism and implementing their ideas.

Unipart Expert Practices
Montvale, NJ

Vice President of USA Operations
2014 to 2016

Built an extension of a UK consulting firm in USA, including delivery, practice development capabilities, and Unipart Way for the Americas. Developed client transformational processes and executive leadership accountability.

• Produced revenues of $12 million each of the first two years and a third-year contract of $8 million.
• Built US team from 8 to 54 consultants in 18 months.  

NBTY
Smithtown, NY

Operational Excellence (O-Ex) Director
2013 to 2014

Built Op-Ex capabilities and the execution of Op-Ex projects across Supply Chain operations. Planned and implemented Op-Ex systems across NBTY. Directed operations and coached improvement projects.

• Reduced changeover times by 72% across packaging lines by conducting kaizen events with cross functional teams.

• Designed and implemented pull systems that increased daily output from an average of 387K bottles a day to 550k and reduced overtime from 38% to 14%.

Dr. Pepper Snapple Group
Plano, TX

Senior Director
2010 to 2013

Evaluated operations and designed a strategy in Rapid Continuous Improvement. Promoted to Senior Director to realign RCI. Led  and deployed Lean development, training, mentoring, and certification for 22,000+ employees across 159 sites.

• Trained over 1,800 DPS employees in 2011. Devised Enterprise Lean Strategies for 2013 and beyond for company-wide Lean/Six Sigma tools for all employees. Developed corporate-wide 5S Training for 2012, which included scripting a video series for 22,000 employees.

• Directed 13 team members in completing 67 Kaizen events that realized $87 million in savings over 2 years.

• Formulated a strategy of Super Kaizen events that included 3-5 Kaizen events within the same week, which yielded $1 million to $5 million in savings per event.

• Pioneered the implementation of 32 Super Kaizen events and 31 other events yielding $87 million in savings in Supply Chain and Sales improvements for USA/Mexico operations.

Flowcycle LLC.
Plano, TX

Founder/CEO
1994 to 2010

Developed and managed Lean/Six Sigma for process improvement operations, software and education consulting practices, business development, sales, project management, change management, client relationship management, and client solution delivery. Oversaw team of 27 consulting professionals to a peak of $6.5 million in annual revenue.

• Achieved over $2 billion in cumulative cost savings for client base utilizing Lean methods and practices.
• Accrued $3 million in annual productivity improvements for Metro Labels Printing Company by establishing training programs that promoted smooth employee transitions and faster cycles of learning.
• Redesigned the manufacturing process for Parker Hannifin Green Camp Plant by mobilizing the plant through training workshops and redesigning jobs to eliminate steps, which resulted in $7 million per year in cost savings.
• Reduced backlogged orders from $600,000 to less than $70,000.
• Cut cycle times by 80% and reduced the age of the oldest order from 90 to 30 days.
• Reclaimed over 70,000 square feet of factory floor space and cut inventory by 66%.
• Played a key role with client company, Parker Hannifin,  awarded “Best Lean Plant Operations in Ohio.”

SNE Enterprises, INc.
WAUSAU, WI

Director of Logistics – Reporting to the CEO
1992 to 1993

Operational responsibility for information systems, purchasing, production control, inventory control, supply chain management, and transportation at manufacturer of Vetter, Crestline, and Visions branded windows and doors with $280 million in annual revenue. Administered $140 million operations and inventory budget.

• Drove revenue growth 70% (+$100 million) in one year by re-inventing window customization manufacturing process and reducing cycle time from 8 weeks to 2 days
• Boosted on-time delivery rate from 69% to 98% and reduced back orders to less-than 1%

George Group
Dallas, TX

Director
1988 to 1992

Executed projects involving lean manufacturing practices for electronics, metal fabrication, processed foods, and assembly plant clients at a boutique consulting firm. Lead contact for client interactions and product delivery. Developed curriculum for becoming a certified CFM-Lean Black Belt Coach/Consultant (Train-the-Trainer Program).

• Directed the ITT corporate-wide Lean project at 17 plants in Germany, Italy, Mexico, and the US, resulting in a decrease of average cycle time between 50-70% per plant while improving quality.
• Developed the supply chain strategy at Hill’s Science Diet Pet Food, which reduced can packaging material inventory by 90% while eliminating two buildings dedicated to empty cans.
• Led 10 teams of 150 Union Members of Machining in the first “U” Shape Assembly Cell at Allied Signal, which resulted in a 70% reduction in cycle time.

IBM
Austin, TX

Staff Manager
1978 to 1988

Established a Participate People Program and reduced labor codes from 175 to 15. Taught CFM concepts and Kanban design to 2,000 employees Added a vertical cross-training program that provided flexibility for production workers. Reduced cycle time from 45 days to 4.5 days.