Recent Projects
Optimized Layout: Wall Panel Plant Material Flow – studied the layout and staffing of a manual assembly process of wall panels; determined best re-balance of operator assignments/duties to smooth the flow and avoid bottlenecks.
Recent Projects
Process Improvement: Truck Turnaround Time Reduction – studied the flow and layout of lumber truck turns in the Main Yard; developed two loading zones and coordinated work of pickers, stagers, loaders, and drivers to reduce truck turns by 50% over the first three months.
Recent Projects
Process Improvement: Developed and facilitated senior management “kaizen team” to oversee and direct process improvement activities; developed top five metrics for management to monitor and evaluate production and inventory control performance. Woodstock, IL.
Recent Projects
Streamline Warehouse Shipping/Receiving Process: Developed current state value stream map to identify areas of improvement in the warehouse of a millwork production facility, focusing on the flow of purchased and received materials through shipment; resolved top issues; created future state map; developed and rolled out implementation plan; conducted training; and wrote documentation. Jessup, MD.
Recent Projects
Training & Coaching: Advised senior management team on transition of the CEO to position of Chairman, the President to President and CEO, and provided operations performance analysis to the COO.
Recent Projects
Lumber/Millwork Manufacturing Streamline Work Order Execution Process: Developed current state value stream map to identify areas of improvement in the creation and execution of production work orders; resolved top issues; created future state map; developed and rolled out implementation plan; conducted training; and wrote documentation.
Introduce 5S/Lean Principles to Door/Millwork Shops (2 Locations): Took baseline pictures and assessed current state of facility relative to organization/cleanliness; developed and presented training materials for staff to learn/understand continuous improvement principles; coached staff leaders on implementation strategy.
Optimize Door Shop Warehouse Layout: Determined top-selling SKU’s to prioritize which products should be organized and located to facilitate most efficient flow of materials and labor; established baseline layout of equipment, machinery, labor, materials, and supplies; evaluated several layouts and compared to management criteria for best method for flow of labor and products; organized implementation plan to facilitate improvements.
Recent Projects
Process Improvement: Developed current state information process and Value Stream Maps of the truss quote-to-cash process; acted upon over thirty kaizen bursts, focusing on production control and product flow improvements.
Optimized Layout: Developed template of truss machinery and auxiliary equipment to determine best layout within several potential new buildings in various locations around the current truss plant.
Recent Projects
Streamline Window Field Service/Repair Process: Developed Current State process map, determined kaizen bursts for improvements to process steps, tested changes, and implemented Future State process map with documentation and metrics.
Streamline Architectural Hardware Order/Installation Process: Developed Current State process map, determined kaizen bursts for improvements to process steps, tested changes, and implemented Future State process map with documentation and metrics.
Streamline Estimating Process: Developed Current State process map, determined kaizen bursts for improvements to process steps, tested changes, and implemented Future State process map with documentation and metrics.
Optimize Lumber Yard Layout: Determined top-selling SKU’s to prioritize which products should be organized and located to facilitate most efficient flow of materials and labor; established baseline layout of equipment, machinery, labor, materials, and supplies; evaluated several layouts and compared to management criteria for best method for flow of labor and products; organized implementation plan to facilitate improvements.
Streamline Credit Return Process: Developed current state value stream map to identify areas of improvement in receiving, evaluating, and issuing credit for returned products; resolved top issues; created future state map; developed and rolled out implementation plan; conducted training; and wrote documentation.
Develop Operational Metrics: Determined top three to five performance variables to monitor production/service performance; developed data collection methods and spreadsheets to track daily results; developed and posted charts with targets for analysis and improvement.
Recent Projects
Optimize Production Layout: Determined optimal product flow through five-step production process, reduced batch sizes to institute single-piece flow and production smoothing; trained production operators and management on 5S/Lean concepts and principles.
Streamline Truck Turnaround Process: Determined critical elements of truck turnaround process (external/internal/external times); established metrics for weekly tracking of turnaround performance; trained production operators and management on 5S/Lean concepts and principles.
Recent Projects
Metrics and Corrective Action: Worked with senior management team to identify and develop five critical business metrics; developed guidelines and facilitated first three months of management review meetings. Unionville, CT.
Optimized Layout: Identified current state conditions for the yard and millwork warehouse and developed several options for improving product group layout. Avon, CT.