Casting/Machining Operations Leader (215158) MBA / Die Cast, Foundry, Green Sand, / Aluminum, Gray Iron, Ductile Iron, Brass, Bronze / Automotive, Aerospace, Heavy Industrial and Off-Road industries / Will Relo

20+ years of progressive experience in the Foundry and Machining the Aerospace, Automotive, Heavy Industrial and Off-Road industries He has 2 MBAs, one in accounting and one in management. He has broad experience in multiple types of metal and casting processes and machining operations. He is highly skilled in adherence to processes and procedures and through quality planning and training, as well as supplier and customer negotiations to effectively reduce costs and adherence to regulatory compliance. He is a leader that can improve your foundry operations, quality and processes. He knows how to keep clients happy through communication, improved product quality and cost reduction. . He is single, and willing to relocate for the right opportunity! Better hurry as talent like this does not last very long! His notable experience includes:

• Acquisition of new contract (outside) work.
• Oversee foundry maintenance for equipment to reduce diminishing returns on equipment.
• Research and analysis for capital expenditures on foundry and heat treat and finishing operations equipment.
• Negotiated with suppliers to acquire price concessions.
• Controlling labor costs both in-house and contract by reducing overtime.
• Facilitated the purchase and installation of new Disamatic molding line resulting in $5.5M first-year scrap savings and $152K annual labor savings.
• Reduced operational costs by reducing machine downtime and moving constraints to gain the highest possible machine productivity thereby increasing OTD from 88% to 97%.
o Cost savings yielded a 1.4% ($1.54MM) increase in EBT.
• Increased profitability through cost and scrap reduction (from 2.6% to 1.8% COGS, $4.4M savings)
• Utilized 6-Sigma methodologies to reduce operational costs, inventory and lead times.
o Increased inventory turns from 10.6 to 15.2.
• Negotiated with foundry vendors for pricing reductions and quantity breaks yielding a first year savings of $1.054M.
• Increased P&L by implementing programs to reduce foundry and machine scrap through vendor and supplier contact and implementation of scrap/cost reduction programs and assisting on ISO functions.
• Implemented cost and quality improvement of purchased and manufactured products through APQP process and supplier and customer contact and re-engineered existing product for manufacturability resulting in lower cost and more expedient turnaround on product release and delivery yielding $1.58M in savings.
• Worked with 46 domestic foundry operations and 6 offshore foundry operations sourcing and re-sourcing iron, and aluminum components.
• Managed internal manufacturing process improvement yielding an annual manufacturing cost and labor savings of $1.32M.
• Reduced scrap through implementation of control plans and assisting on ISO functions.
• Improved quality and reduced through monitoring internal scrap and returns as well as improving manufacturing capability of product.
o Reduced internal scrap 50% through evaluation of processes and tooling.
• Negotiated customer contracts on new product and transfer product, resulting in a 3% one-year increase in business.
• Reduced suppler base to ensure JIT delivery, lower inbound shipping costs, and implemented competitive quoting of purchased product.
• Reduced finishing operation cost by 60% with process improvements, and labor reduction through improved product, production techniques, elimination of excessive handling, yielding an average labor savings of $168K annually.
• Saved $108K by analyzing and utilizing scrap machinery and inventory of scrap with indeterminate chemical origin, for use in production.
• Replaced standard charge material costing $185/ton with better material costing $105/ton saving $153K annually.
• Utilized existing equipment to replace obsolete high-maintenance equipment, saving $38K in annual maintenance costs.
• Lowered energy demand by predicting usage and effective scheduling saving $300K annually.
• Cooperated with IDEM and EPA to insure a seven-year span with a record of zero non-compliance reports or fines.

• Foundry Operations
• Die Casting Operations
• No Bake Casting
• Lost Foam Casting
• Green Sand Casting
• Castings Sized Range of .5 to 1600 pounds
• Heat Treating Operations
• Melting Operations
• Pouring Operations
• Solidification Modeling
• Non-Ferrous Metallurgy
• Ferrous Metallurgy
• Assembly Operations
• Core Manufacturing
• Tier 1, Tier 2 Automotive
• Automotive Castings
• Developing Risering Techniques
• Developing Gating Techniques
• Solving Shrinkage Problems
• Solving Porosity Problems
• Raw Material Controls
• Melting Operations
• Molten Metal Filtration
• Pouring Operations
• Quenching Heat Treatment
• Annealing
• Reducing Cycle Times
• Manufacturing Process Quality
• Tooling Quality
• Process Control
• Creating SOP Training
• Ford Q1
• Reducing Labor Costs
• Scrap Reduction
• Improving Overall Equipment Effectiveness (OEE)
• TS16949
• TS Audits
• 6D
• 8D
• PPAP Submissions
• Product Engineering
• Product Launch Activities
• APQP
• Conducting Design Reviews
• Continuous Improvement Goals
• Cost Estimating
• Reducing Costs
• Design Of Experiments (DOE)
• Developing Cost Effective Manufacturing Processes
• ERP – SAP, Bliss
• Gage R&R
• Developing Work Instructions
• Improving Jigs / Fixtures
• Kaizen Events
• Material Management
• P & L Responsibility
• PFMEA
• Engineering Change Notification
• Project management
• Providing Technical Support
• Root Cause Analysis
• Visual Systems
• Quality Management
• Production Quality experience
• Internal Quality system audits
• Re-engineering Existing Product for Manufacturability
• Minimizing Scrap / Rework
• Improving Profitability
• External Quality system audits
• Setting Up Quality Systems
• Component Design Review
• Ensuring Specifications
• ISIR Submissions
• Statistical Investigations
• New Product Development
• Control Plans
• Analyzing Production Limitations
• Raw Material Controls
• Ensuring Dimensional Accuracy
• ISO 9001, ISO 14001
• Increasing Inventory Turns
• Hi Volume CNC Machining
• Machining Data Collection
• CNC Lathes
• CNC Milling Machines
• Control Charts
• Designing Fixtures
• Manual Fixturing
• Hydraulic Fixturing
• Machining Operations
• Aluminum
• Gray Iron
• Bronze
• Copper
• Ductile Iron
• Brass

EDUCATION
• Master of Business Administration (MBA), Accounting
• Master of Business Administration (MBA)
• Bachelor of Science, Accounting /