Personal Profile
I am a company representative, a customer advocate, and a cross-functional leader with 21 years of aircraft manufacturing experience for the world’s largest Tier 1 aerostructures manufacturing company delivering large commercial and military aircraft components according to ISO9001 and AS9100 quality standards. I am passionate about applying Toyota Production System (TPS) methodologies to break process bottlenecks improving throughput, decreasing inventories, and reducing operating expenses.
Key Skills
Quality Management System (QMS)
• Managed execution and performance with the balanced scorecard framework and standardization of best practices in the industry.
• Improved the cost position of the company by reducing product cycle time (50% of current total wait time) and reducing raw material 30%, work in process (WIP) 30% - 50%, and finished goods inventories 20%.
• Knowledgeable in inventory buffer management (time/replenishment/shipping) and kitting methodologies.
• Championed EHS standards regarding personal protection equipment (PPE), machine guarding, and housekeeping.
• Performed warehouse inventory and shipping/receiving audits to facilitate the control of return goods and to manage nonconforming materials.
Leadership Experience & Team Building
• Managed 50 unionized shop employees in multiple work centers to fabricate parts per master schedule.
• Employed a transformational leadership style to develop employees into leaders through coaching and training.
• Empowered employees by providing quantitative data to make independent business decisions.
• Assembled dynamic and diverse teams to improve “world class” organizational goals and objectives (KPIs of Quality, Cost, Delivery, Safety, and Team) to deliver sustainable processes, reduction of inventories, and improvements in the velocity/throughput of parts and materials.
• Excellent communication skills with senior managers, shop managers, and employees to extract critical information and to provide superior customer satisfaction.
Continuous Improvement
• Instructor for Lean (eliminate waste), Six Sigma (decrease variation), and Theory of Constraints (TOC) (identify and mitigate bottlenecks) methodologies, tools, and processes.
• Applied DMAIC principles, root cause corrective action (RCCA), bias for quality (BFQ), rapid response teams, mistake proofing (poka-yoke), and first pass yield (FPY), and the five focusing steps of TOC tools to improve scrap occurrences.
• Developed value stream maps (VSM), standard work, 5S databases and auditing, 7 elements of surgery, flow and TAKT times, And On and shop pacer visual signals, cross-training matrices, total productive maintenance (TPM), rules in use, and Kanban systems to improve manufacturing processes.
• Performed statistical process control (SPC) analysis to determine the standard deviation in order to understand normal versus variance conditions.
• Innovative and creative database/dashboard design to ensure product compliance, to conduct process performance analysis, and to identify and correct nonconformance issues.
Key Achievements
• Created a Buffer Management Tool (BMT): A single-prioritization production order report to improve throughput in all manufacturing operations by reducing WIP inventories 30%-50%.
• Documented cost savings of $1.2 Million in 2011, $6.4 Million in 2012, and $1.5 Million in 2013 in time savings and process improvements.
• Reduced WIP inventory in the web router shop 65%, reduced scrap 15%, 90% reduction in passing on ahead-of-schedule work, and 80% reduction of two-man loading. Choked the release of orders and adopted an “effectiveness over efficiency” approach to production order management. Designed a remote nesting process to create digital nests from home reducing delivery time to the customer 83% from 3.0 hours to 0.5 hours.
• Established electronic shop pacer boards to provide hour-by-hour visibility on progress toward daily customer demand leading to a 10%-20% gain in attainment in most areas by leveraging peer pressure in performance.
Employment
Floyd Consulting Wichita, KS 2013 – Present Owner
• Data sharing improvement specialist.
Boeing Company / Spirit AeroSystems - 21 years of combined service with the following three organizations:
Spirit AeroSystems Wichita, KS (2010 –August 2013) Lean Relation Manager / Industrial Engineer
• Advised senior managers on lean strategies, execution, and goal attainment following the QCDSM model.
• Designed, implemented, supported BMT / shop pacer boards to reduce WIP and satisfy customer demand.
• Subject Matter Expert (SME) pursued by directors, product line managers, shop managers, and employees to build advanced databases to improve information flow and organizational performance.
• Cultivated a Lean Maturity Assessment (LMA) database to capture, store, and retrieve audit information with the use of electronic forms.
Wichita, KS (2008 - 2010) IT Business Solutions Analyst
• Combined data from multiple SAP reports to build a sub-assembly lot time report; reduced effort form 45 hours per day to 3 hours per day.
• Created a specific product database to identify recurring material shortages, craft a historical dat...
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