Alan Sheaffer Email & Phone Number

Temecula, CA, US

Seattle, WA, US

San Diego, California, US

• Built a 4 person IE team to drive efficiencies for the retail distribution network and Omni-channel supply chain. Directed the DC Labor Management and Pay-for-Performance programs. Supported distribution network.
• Managed the Manhattan Labor Management and Slotting Optimization solutions for the Distribution network.
• Directed LM rollouts in 3 main Distribution Centers achieving over 10% improvement in overall building performance.
• Drove slotting initiatives to optimize picking performance and minimize store stocking time, contributing to $2.2M in annualized savings.
• Led eCommerce improvements in process flow, workstation design and the customer experience.
• Created initial slotting profiles for the new 770,000 SF Distribution Center in Reno, NV.

San Diego, California, US

• Identified, recommended and implemented operational improvements for the national Supply Chain network.
• Configured the first site for the Manhattan Labor Management program and built the template for future sites.
• Developed the slotting plan for the new 780,000 SF Distribution Center in Cranbury, NJ and created the interface to seamlessly upload the initial configuration to the Manhattan WMS.
• Led the decommissioning of 2 DCs (Cranbury and Monroe, NJ) with successful transitions to the respective landlords, on-time and under budget.

Broomfield, CO, US

• Managed the Labor Management and Associate Incentive Program for the Americas. Built a team of 3 associates to maintain standards and provide clerical support for the program. Provided operational support and direction.
• Implemented the Manhattan Associates Labor Management system to track performance for the incentive system – “ATM-Achieve the Money”. Delivered $100K in measurable efficiency improvements in the first 26 weeks.
• Reduced regular 2nd shift shipping workforce by 6 people in the first week of study by balancing workload.
• Introduced Pick & Pack Singles carts for E-commerce to reduce touches and handling costs.
• Led changes in racking configurations and slotting optimization. Improved active picking efficiency by 60% in 2 aisles by adding 360 locations, eliminating the need for high-bay unit picking.
• Developed model to predict monthly distribution center costs based on forecasted units by order type.

San Diego, California, US

• Identified, recommended and implemented operational improvements for the Distribution Centers on a national level. Developed measurement techniques and standards to track performance. Managed Engineered Labor Standards.
• Developed processes for the ABCD Cycle Count program. Led program implementation and third party audit preparations at the Distribution Centers. Program eliminated the need for 4-wall inventories.
• Collected times and developed Engineered Labor Standards for the Labor Management System roll-out in FY2010. Validated times and reenergized the Productivity Performance Manager tool using single-variable standards to.
• Created a forecasting tool to predict distribution center costs based on SKU placement within the various flow path types.
• Improved E-commerce activities by implementing Lean principles, generating a 20% increase in packing throughput and picking efficiency.

US

• Offered engineering solutions for a proposed manufacturing facility in Puerto Rico.
• Evaluated vacant building in Guanica, PR
• Developed manufacturing design and equipment requirements for the new facility.
• Directed purchase of surplus equipment stateside and containerized for delivery to PR.

US

• Directed other engineers in executing capital improvements projects and layout modifications at up to 23 manufacturing centers in 14 states. Championed the Division’s Lean manufacturing efforts. Produced code approval.
• Initiated the Housing Division’s Lean focus with 5S and value stream mapping. Generated $472,000 in annualized labor savings and eliminated 5404 miles of excessive travel by improving existing processes at 5.
• Launched a new products division, Trendsetter Homes, by designing the production line layout, defining the initial product specifications and developing pricing for all startup modular product lines and options.
• Influenced the initial design-for-manufacture of the UEPH military housing project for Fort Bliss. This project generated $20M in sales for fiscal year 2008, and became a springboard for projects at Ft Leonard Wood and.
• Successfully closed 60 potential recall cases in fiscal year 2009 by analyzing the Federal Regulations and authoring all communications to the appropriate agency. Developed ongoing training procedures for plant Quality.
• Managed the Division’s Environmental Health and Safety (EHS) department.

US

Led a 3 person team in creating a master parts file with standardized BOM subassemblies from 17 independent systems for implementation in JD Edwards. Published unit pricing updates and tabulated quarterly margin analyses for the Senior Vice President. Supervised facility improvements for the $1.3M 94,500 square foot facility start-up in Perris, CA.

US

• Managed a staff of 4 (2 Engineers and 2 Drafting associates). Estimated costs, defined scope of work, and scheduled all plant process and safety improvements. Developed preventive maintenance schedules for common.
• Created the electronic weekly manufacturing reporting system for key metrics (productivity, efficiency, capacity utilization, etc.)
• Provided guidance and advice to the Manufactured Housing Research Alliance (MHRA) on their report to HUD titled “Getting Lean: Assessing the Benefits of Lean Production in Factory Built Housing”
• Selected to visit Japan as part of an elite delegation to study applied Lean principles.
• Resolved product quality issues as a contributing member of the Service & Warranty Action Team producing $342,000 in annualized savings to the corporation.

US

• Promoted to Senior Engineer in Sept 1998Orchestrated full manufacturing plant set-ups with direct budget responsibility to $3M per project, including designing work cells, procuring parts, hiring contractors, tracking.
• Achieved 60% gains in output (per direct labor hour) in a 6-month period at 2 plants.
• Completed the 16-week set-up of a $3M, 89,000 square foot facility in Virginia.
• Identified $15.7M in annual contribution margin potentials at 11 plants.
• Received Kaizen tool belt knowledge from TBM consultants, augmented by participation in the Kaizen exchange event in Knoxville, TN.
• Trained as a Competent Person for Fall Protection and Rescue Training by Gravitec.

Integrated sales, purchasing, costing, engineering, and service functions electronically using relational databases on a UNIX-PC network. Provided user support to all staff. Successfully implemented a conversion to an Informix-based accounting system for G/L, A/P, A/R, and Payroll.

Established product pricing for new and non-standard units, including government and export projects. Developed the system for tracking Bills of Materials (BOM). Maintained the Master Production Schedule (MPS). Coordinated the PEECH (PA Energy and Environment Concept Home) project with the Pennsylvania State Energy Office, Berks County Vo Tech and.

Performed classical IE studies (layout and methods analysis, time studies, fixturing) while working as a technical salesperson of modular homes.

Bachelor Of Science, Industrial Engineering

Bachelor Of Arts