Daniel Nichols Email & Phone Number

Prince George, Virginia, United States

PGT Innovations was a premier manufacturer of highly engineered and technically advanced windows and doors. In 2023, PGT founded Triple Diamond Glass to fabricate triple-pane IGUs & laminates featuring ultra-thin Corning Architectural Technical Glass (ATG) for external window & door manufacturers. In 2024, Miter Brands acquired PGT. Miter elected to internalize products featuring ATG & absorb Triple Diamond’s manufacturing capabilities into existing facilities. Triple Diamond Glass facility is… Show more PGT Innovations was a premier manufacturer of highly engineered and technically advanced windows and doors. In 2023, PGT founded Triple Diamond Glass to fabricate triple-pane IGUs & laminates featuring ultra-thin Corning Architectural Technical Glass (ATG) for external window & door manufacturers. In 2024, Miter Brands acquired PGT. Miter elected to internalize products featuring ATG & absorb Triple Diamond’s manufacturing capabilities into existing facilities. Triple Diamond Glass facility is scheduled to close at year-end.PLANT MANAGERPrince George, VA■ Led on-site brownfield start-up team for 291k sqft high-volume custom residential flat glass fabrication facility equipped to process traditional float and ultra-thin glass into innovative fenestration solutions.■ Original value proposition: fabricate thinner, lighter glass components as drop-in solutions, enabling window and door manufacturers to meet EnergyStar 7.0 with existing framing and hardware systems.■ Pivoted quickly in response to major shifts in corporate strategy. Analyzed potential internal supply opportunities. Following acquisition, managed shutdown including release of staff. Then, due to unexpected supply chain interruption, restarted facility within 2 weeks. Leveraged equipment to manually fabricate high-volume tempered glass cut from stock sheets without supporting software.■ Completed Vitro Certified Fabricator and Guardian Select Fabricator program requirements. Show less

Hawthorne, California, United States

TRÜ Architectural is a fabricator and subcontractor of curtain wall, window, door and façade systems for luxury residential and boutique commercial new construction projects. TRÜ partners with leading system providers to locally design, build and install custom engineered fenestration solutions.OPERATIONS MANAGERHawthorne, CA■ Operational responsibility for non-union glazing contractor with robust engineering and fabrication capabilities. Acting controller and legal… Show more TRÜ Architectural is a fabricator and subcontractor of curtain wall, window, door and façade systems for luxury residential and boutique commercial new construction projects. TRÜ partners with leading system providers to locally design, build and install custom engineered fenestration solutions.OPERATIONS MANAGERHawthorne, CA■ Operational responsibility for non-union glazing contractor with robust engineering and fabrication capabilities. Acting controller and legal coordinator. Annual sales confidential, 60 employees.■ Designed new plant layout and consolidated existing operations into one building. Managed the repairs and subsequent lease of former second building, generating ~$500k in annual revenue.■ Reduced turnover 55% by building a strong culture, implementing skill-based hourly compensation strategy to incentivize mentorship and emphasizing promotion from within. Enhanced retention reduced errors, improved quality and proved key in transforming the status quo into a virtuous circle.■ Emphasized safety and claims management to attain 3-year EMR of 0.79 in 2023 vs 1.45 in 2017.■ Coordinated successful applications for ERTC, R&D tax credits and PPP loans worth $3.3M. Coordinated refinance of real estate holdings and line of credit. Managed covenant compliance.■ Developed and implemented cost control tool to enhance financial visibility into ongoing projects.■ Continuous improvement: Encouraged creative thinking and guided/assisted team in finding lean, innovative solutions to minimize non-value-added activities. “More, better, faster, cheaper.”■ Authored shop floor software to communicate setup instructions for profile knurling/rolling, facilitate production tracking, enable real-time lineal profile cutting optimization, and require completion of quality assurance record keeping as a precursor to generating interim and finished product labeling. Show less

Cerritos, Ca

West Coast provides value-added flat glass products to high-end custom residential window and door manufacturers throughout Southern California, Southwest Nevada, and Western Arizona. Manufacturing processes include cutting, fabrication, tempering, laminating and insulating with grid/SDL bars.GENERAL MANAGERCerritos, CA■ New position tasked with establishing KPI-based incentive plan, creating visibility into existing business system data, implementing general and… Show more West Coast provides value-added flat glass products to high-end custom residential window and door manufacturers throughout Southern California, Southwest Nevada, and Western Arizona. Manufacturing processes include cutting, fabrication, tempering, laminating and insulating with grid/SDL bars.GENERAL MANAGERCerritos, CA■ New position tasked with establishing KPI-based incentive plan, creating visibility into existing business system data, implementing general and industry-specific best practices, and coaching the team to identify OFIs and implement effective solutions. Annual sales confidential, 65 employees.■ Authored fully automated, real-time KPI reporting software which uses TV monitors to display results for safety, quality, on time delivery, backorders, internal wastes and key productivity metrics.■ Engaged team to improve optimized glass yields 3-5% by consolidating like-kind SKUs, defining best practices for minimizing remnants during the scheduling process and reducing trim parameters. o Facilitate production scheduling, BOM-based raw material purchasing and capacity planning. o Simplify research of order status and related manufacturing transactions. o Categorize and summarize booking, invoice, backlog and open manufacturing requirement data. o Manage the employee attendance point system, monitor daily delivery truck safety inspections, and streamline quality assurance record keeping (created, not yet fully implemented).■ Directed team in becoming a Guardian Certified Fabricator, attaining SGCC certification, maintaining IGCC certification, and designing an intersect key for a new SDL bar. Show less

Gloucester City, Nj

Thermoseal provides innovative glass and door solutions to manufacturers of commercial bottle coolers, refrigerated reach-in cases, product display cabinets, vending machines, and warming appliances found in grocery stores, convenience stores, restaurants, bakeries, and bio-medical laboratories.DIRECTOR OF OPERATIONS / GENERAL MANAGERGloucester City, NJ Facility■ Operational responsibility for unionized glass door and frame manufacturing facility. Lead cross-functional… Show more Thermoseal provides innovative glass and door solutions to manufacturers of commercial bottle coolers, refrigerated reach-in cases, product display cabinets, vending machines, and warming appliances found in grocery stores, convenience stores, restaurants, bakeries, and bio-medical laboratories.DIRECTOR OF OPERATIONS / GENERAL MANAGERGloucester City, NJ Facility■ Operational responsibility for unionized glass door and frame manufacturing facility. Lead cross-functional team within matrix organizational structure. Annual sales confidential, 60 employees.■ 3-year financial results: Team increased revenue 59%, enhanced gross margin 13.7% of sales, and boosted gross profit dollars 123%, attracting private equity firm to acquire the business in 03/2015.■ Product development: Team designed, tooled, and launched six distinct families of configurable products, and reengineered existing products to enhance performance and reduce manufacturing, packaging, and freight costs. Additional innovations planned for 2016/2017. Named in two Thermoseal provisional patent applications.■ Project management: Team consolidated glass and door/frame operations into one facility following purchase and $2.5MM+ renovation of 80-year-old facility. Designed 150,000 sqft plant layout and specified/sourced $1MM+ of equipment to support growth and enhance fabrication capabilities. Additional capital equipment planned for 2016/2017. ■ Continuous improvement: Encourage creative thinking and guide/assist team in finding lean, innovative solutions to minimize non-value-added activities. “More, better, faster, cheaper.”■ Data analysis & programming: Authored software to supplement business system tools, including quoting, production scheduling, automated dashboard and corporate reporting, smart BOMs, customer-specific product labeling, and construction expense tracking. Active projects include order-specific electronic work instructions, and enhanced shop floor control tools. Show less

Plymouth, Mi And Bridgeport, Nj

Trulite Glass & Aluminum Solutions is one of North America's largest architectural glass and aluminum fabricators and distributors. With its unmatched product line, Trulite has created a Total System Approach to satisfy virtually any architectural glazing requirement.BRANCH MANAGERBridgeport, NJ Facility■ Assigned to devise turn-around plan for unprofitable glass fabrication plant with long standing reputation for inconsistent quality/service. Annual sales of $10M with 55… Show more Trulite Glass & Aluminum Solutions is one of North America's largest architectural glass and aluminum fabricators and distributors. With its unmatched product line, Trulite has created a Total System Approach to satisfy virtually any architectural glazing requirement.BRANCH MANAGERBridgeport, NJ Facility■ Assigned to devise turn-around plan for unprofitable glass fabrication plant with long standing reputation for inconsistent quality/service. Annual sales of $10M with 55 employees.■ Upgraded team, streamlined product offerings, raised daily pricing and focused on reducing rework.■ Increased revenue 21% from 2011 to 2012 without capital investment and improved EBITDA 12%.■ Managed thru the industry-wide economic downturn and the divesture of multiple facilities.OPERATIONS MANAGERPlymouth, MI Facility■ P&L and operational responsibility for non-union glass fabrication facility specializing in heavy glass and commercial insulated glass units. Peak annual sales of $15M with 70 employees.■ Shifted the culture and restructured the operation to shorten lead-times, increase capacity, improve customer service and achieve the flexibility required to accommodate rush orders.■ Increased revenue 40% from 2007 to 2008. Attained distinction of 2nd most profitable UGC facility.■ Implemented PMC optimization software and authored quoting and procurement software to semi-automate labor intensive office functions and reduce administrative staff from 11 to 7. Show less

Carlisle, Pa, Witchita Falls, Tx And Burlington, Ia

PPG has 140+ manufacturing facilities and affiliates operating in 60+ countries. PPG is a leading manufacturer of flat glass that is fabricated into products primarily for commercial construction and residential applications. Since 1883, PPG has been a technological leader in the glass industry.FLAT GLASS TEMPERING SPECIALIST■ Carlisle, PA: Organized tempering operation, updated work instructions and authored QC software.■ Wichita Falls, TX: Assisted with start-up of a new… Show more PPG has 140+ manufacturing facilities and affiliates operating in 60+ countries. PPG is a leading manufacturer of flat glass that is fabricated into products primarily for commercial construction and residential applications. Since 1883, PPG has been a technological leader in the glass industry.FLAT GLASS TEMPERING SPECIALIST■ Carlisle, PA: Organized tempering operation, updated work instructions and authored QC software.■ Wichita Falls, TX: Assisted with start-up of a new semi-continuous commercial glass tempering line.■ Burlington, IA: Modified process to enable facility to heat-treat post-temperable MSVD coated glass. Show less

Walton Hills, Oh

Consultant: Apr 2002 – May 2002Consultant: May 2003 – Aug 2003Employee: Aug 2003 – Oct 2006Edge Seal Technologies is a privately held custom insulating glass manufacturer servicing the residential window and door industry. Edge Seal specializes in just-in-time, sequenced delivery of annealed, tempered, V-groove, laminated and shaped IG units with decorative muntin options.PROJECT ENGINEER / GLASS FABRICATION MANAGERWalton Hills, OH Facility■ Operational… Show more Consultant: Apr 2002 – May 2002Consultant: May 2003 – Aug 2003Employee: Aug 2003 – Oct 2006Edge Seal Technologies is a privately held custom insulating glass manufacturer servicing the residential window and door industry. Edge Seal specializes in just-in-time, sequenced delivery of annealed, tempered, V-groove, laminated and shaped IG units with decorative muntin options.PROJECT ENGINEER / GLASS FABRICATION MANAGERWalton Hills, OH Facility■ Operational responsibility for glass cutting, V-groove and tempering work centers. Annual production of 18M square feet with 45 employees.■ Reduced OSHA incidence rate by 75% over two years and achieved 150+ days worked safe.■ Improved productivity of tempering operations from 85 to 130 units per labor hour.■ Coordinated implementation of capital projects, including installation of new CNC glass cutter, continuous tempering oven extension and a variety of process control improvement projects.■ Authored software to extract and analyze key process indicators from existing business systems. Show less

Riviera Beach, Fl

Security Impact Glass formed to commercialize proprietary bonding film technology into impact resistant, bullet resistant, blast resistant and fire resistant glass-clad polycarbonate laminates. Security Impact Glass has reorganized several times since 2003 and became Saf-Glas, LLC in 2006.GENERAL MANAGERRiviera Beach, FL Facility■ Assigned to devise turn-around plan for three-year-old glass-clad polycarbonate laminating manufacturer utilizing proprietary technology. Annual… Show more Security Impact Glass formed to commercialize proprietary bonding film technology into impact resistant, bullet resistant, blast resistant and fire resistant glass-clad polycarbonate laminates. Security Impact Glass has reorganized several times since 2003 and became Saf-Glas, LLC in 2006.GENERAL MANAGERRiviera Beach, FL Facility■ Assigned to devise turn-around plan for three-year-old glass-clad polycarbonate laminating manufacturer utilizing proprietary technology. Annual sales of $5M with 35 employees.■ Identified chemical compatibility and product durability issues resulting in field delamination over time, explored edge sealant solutions and recommended re-engineering the bonding film. Show less

Lithia Springs, Ga

Oldcastle Glass is a leading supplier of building envelope solutions and fabricated architectural glass products. Oldcastle Glass merged the management of its Lithia Springs, GA and Stone Mountain, GA facilities in 2002 and merged both operations into a new Atlanta, GA facility in 2007.GENERAL MANAGERLithia Springs, GA Facility■ Assigned to devise turn-around plan for unprofitable insulating glass fabrication plant with declining sales and inconsistent quality/service… Show more Oldcastle Glass is a leading supplier of building envelope solutions and fabricated architectural glass products. Oldcastle Glass merged the management of its Lithia Springs, GA and Stone Mountain, GA facilities in 2002 and merged both operations into a new Atlanta, GA facility in 2007.GENERAL MANAGERLithia Springs, GA Facility■ Assigned to devise turn-around plan for unprofitable insulating glass fabrication plant with declining sales and inconsistent quality/service. Annual sales of $10M with 60 employees.■ Completed installation of laminating line and managed facility thru a difficult transitional period. Show less

Richburg, Sc, Geneva, Ny And Lewistown, Pa

Guardian Industries is a worldwide manufacturer of float glass and fabricated glass products for the automotive and construction industries. Guardian employs 18,000 people and operates facilities throughout North America, Europe, South America, Asia, Africa and the Middle East.PRODUCTION MANAGER / PLANT ENGINEERLewistown, PA Facility■ Operational responsibility for unionized glass fabrication plant specializing in laminated glass, mirror and distribution. Annual sales of… Show more Guardian Industries is a worldwide manufacturer of float glass and fabricated glass products for the automotive and construction industries. Guardian employs 18,000 people and operates facilities throughout North America, Europe, South America, Asia, Africa and the Middle East.PRODUCTION MANAGER / PLANT ENGINEERLewistown, PA Facility■ Operational responsibility for unionized glass fabrication plant specializing in laminated glass, mirror and distribution. Annual sales of $25M with 90 employees. ISO 9002 registered.■ Revamped plant-operating structure to reduce staff 15% and improve efficiencies 8-22%.■ Achieved 150+ days worked without injury and 900,000+ hours worked without a LTA.FABRICATION DEPARTMENT MANAGERGeneva, NY Facility■ Launched fabrication department within a large non-union facility as part of a $125M green field plant start-up team. The new plant earned the distinction of fastest ever to profitability.■ Developed float glass quality control software. Developed interface with plant-wide Intellution HMI software to automatically extract, report and statistically analyze key process data. CUSTOM DEPARTMENT SUPERVISORRichburg, SC Facility■ Responsible for servicing select customers with next-day glass cutting and tempering services in a large non-union facility. Annual sales of $3M with 8 employees.■ Increased throughput 23% by reducing changeover time and consolidating product runs. Show less

Crossville, Tn And Gastonia, Nc

Crossville Rubber and PlastiVax manufactured rubber floor coverings and thermoformed plastics for heavy truck applications. Watermill Ventures (www.watermill.com) acquired Crossville Rubber and PlastiVax in 1994 and divested PlastiVax in 1996 and Crossville Rubber in 2002.PLANT MANAGERGastonia, NC Facility■ P&L and operational responsibility for non-union satellite plastic thermoforming and fabrication facility. Annual sales of $4M with 40 employees. ■ Orchestrated… Show more Crossville Rubber and PlastiVax manufactured rubber floor coverings and thermoformed plastics for heavy truck applications. Watermill Ventures (www.watermill.com) acquired Crossville Rubber and PlastiVax in 1994 and divested PlastiVax in 1996 and Crossville Rubber in 2002.PLANT MANAGERGastonia, NC Facility■ P&L and operational responsibility for non-union satellite plastic thermoforming and fabrication facility. Annual sales of $4M with 40 employees. ■ Orchestrated turn-around of unprofitable plant slated for closure. Increased gross margin by 24.9% of sales and achieved sustained profitability within eight months.INDUSTRIAL ENGINEER / TIME STUDY ENGINEERCrossville, TN Facility■ Conducted time studies and set production standards in unionized facility. Restructured incentive pay program to reduce average earnings 25% and withstood federal arbitration. ■ Negotiated power contract to reduce electric utilities $110k annually. Show less