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Director Manufacturing Operations (209603) Tier 1, 2 Automotive / CNC Machining, Assembly, Injection Molding / Greenfield Operations / International

Michigan-based continuous improvement leader with a 20 year record of accomplishments in quality and productivity with bottom-line profitability in the automotive industry. He is knowledgeable in all facets of operational excellence and manufacturing, Lean Manufacturing, supply chain management, project management, and quality management. His strong leadership, problem-solving, communication, organizational, and negotiation skills are utilized to lead and motivate teams to achieve goals. John has an impressive track record of reducing operating costs and exceeding all profit objectives while maintaining high product quality and customer satisfaction. He has started up facilities globally and in the United States. . He comes highly recommended and is described by other leaders as:

“He is an outstanding, driven leader. He brings a keen technical depth to his relentless pursuit of delivering for customers and to an overall business strategy. He cares about others and not only invests in them but also does not hesitate to “get his hands dirty” in demonstrating how to solve challenging problems!”

“He is a dedicated and gifted leader who excels in balancing the priorities of the business with the skills and personalities of many. He has an incredibly strong drive and commitment to operational excellence, eliminating waste across business/production, and knows precisely how to lead to achieve a common goal.”

He is currently employed in a nonmanufacturing role and is looking for an opportunity to return to an Operations Leadership role in MI, NC, SC, GA, FL, or TN. His notable experience includes:

Establish a new 170,000 sq ft operation in Detroit
Establish greenfield site in TN, project manage the setup, and start operations.
• Led over 15 Kaizens which ranged from complete current and future state value stream analysis with improved average delivery times of 20% and savings of over $90,000.
• Facilitated over 20 SMED / quick changeover events and reduced changeover time by approximately 56%
Decrease spare parts purchasing by 58% through inventory visibility and common part design usage.
• Increase process stability and reduce rejects by 22% by standardizing machine start-up and reaction processes.
• As part of the key team, successfully lead the completion of a turnaround from losing $800,000’s a month in May of 2018 to a net profit of $250,000’s net profit in both Jan and Feb of 2019.
• Implement an APQP/program Management process that resulted in a 72% improvement in program deliverables.
• Achieved 40% waste reduction.

• Meet with customers to mitigate previous deliverable misses. In one specific case, negotiated a walk away agreement avoiding additional financial hardship
• Per the Executive committee agreed upon vision Consolidate operation from 3 facilities to 2 facilities
Increase profitability year over year by 1%+ through this period of time
Consolidate operation from 5 facilities to 3 facilities while reducing labor from 300 employees to the current 193
• Reduce labor from 300 employees to the 193
• Reestablish profitability in early 2009 with an average of 10%
Cut overall operating expenses by 33%
Establish and full implementation of TS 16949 at 3 facilities in the US, Mexico, and Central America

• Ford Q1
• TS16949
• Product Launch Activities
• 6S Experience
• Achieving Cost Reduction
• Continuous Improvement Goals
• Corrective Action
• Cost Estimating
• Design / Layout
• Design Of Experiments (DOE)
• Enterprise Resource Planning
• FIFO Staging
• Gage R&R
• Control Plans
• Developing Work Instructions
• Hiring / Training
• Implementing Continuous Improvement
• Improving Jigs / Fixtures
• ISO9001
• Kaizen Events
• Lean Manufacturing Methods
• Managing Multiple Projects
• Manufacturing BOM
• Material Management
• P & L Responsibility
• Process Capability Index (Cpk)
• Process Failure Mode Effects Analysis (PFMEA)
• Process Manufacturing Improvements
• Project Planning
• Providing Technical Support
• Root Cause Analysis
• Scrap Reduction
• Standard Work
• Statistical Process Control (SPC)
• Supervising Multi-discipline Teams
• Total Quality Management (TQM)
• Troubleshooting
• Value Stream Mapping
• Visual Systems
• 3-axis, 4-axis, 5-axis, 6-axis
• Single Spindle CNC Milling
• Tier 1 / Tier 2 Automotive
• ERP Systems – QAD, AimSolutions
• Reducing Equipment Setup Time
• Mold Design
• Improving Manufacturing Methods
• Implementing CMMS Systems
• Lean Manufacturing
• Managing Machining Operations – Eclipse Mold, iNFLUX
• Project Management
• Quality Documentation
• Reading Blueprints
• Reducing Equipment Down Time
• Work Instructions
• Solidworks