Dan Emerick Email & Phone Number

Nordborg, Dk

Plant Leader of Demand Flow Technology initiative and manager of 5 Engineers and 3 Lean Support Techs. Sustained and improved Lean systems and lead the plant’s productivity projects. Assumed additional responsibility as Maintenance Leader, Product Engineering Supervisor and Project Leader of several commercial quality issues for a key customer.• Lead 4 Kaizen events reducing costs by $240k• Reduced Machining lead time from 6 to 2 days through improved visibility and controlled release of work orders.• Sponsored project to automate Hydraulic testing which reduced cycle time by 80%.• Implemented In-Line particle counter to save $40k and eliminate off-line processes of solvent wash and patch test

Boston, Ma, Us

Project Leader to improve Plant’s part shortages problem (#1 obstacle to on-time delivery) using Oracle’s Min/Max Planning and Auto-Release to Vendors. Accomplished phase 1 of goal in 2.5 months without benefit of formal training or dedicated resources.• Created project timeline and built project team through part-time team members and temps.• Calculated key ordering metrics (safety stock, min/max levels, inventory turns target)• Worked with buyers and vendors to validate data, resolve issues and sustain improvements captured by project.• Turned on Auto-Replenishment/Release, loading data into Oracle using “Dataload” software.

Boston, Ma, Us

Reassumed operations leadership role on request of plant manager after termination of peer. Charged with reestablishing high level of performance, communication and morale. Chosen to create and manage the finished goods ramp-up plan for the transfer of to China.• Attained all project deadlines as a key team member for $1.3M Transfer of Work Project to China.• Improved productivity in PIR Department (Motion Detectors) by 35.1%.• Improved productivity in Glass Break Department (Acoustic and Shock Sensors) by 4.2%.• Improved productivity in MAC Department (Door and Window Switches) by 7.4%.

Boston, Ma, Us

Responsible for recruiting team members and leading Lean Manufacturing Program, sustaining changes and monitoring action items, assisting in pre-event analysis for future Kaizen events and training shop floor associates in Lean philosophy. Goal of Kaizen Events was to identify and eliminate/reduce “the 7 deadly wastes”, establish one piece flow, staff the work-cell by takt time vs. cycle time analysis and sustain improvements through “5S” and visual management (standard vs. abnormality).• Led or facilitated 15 Kaizen Events saving $156K in direct labor, $273K WIP Inv and 844 ft2 floor space.• Created and taught Lean Curriculum to 350 multi-cultural shop floor associates using “The Socratic Method.”• Created 2004/2005 Tualatin Plant’s Lean Plan and successfully presented to GE’s Corporate CIO.

Boston, Ma, Us

Responsible for recruiting team members and leading Lean Manufacturing Program, sustaining changes and monitoring action items, assisting in pre-event analysis for future Kaizen events and training shop floor associates in Lean philosophy. Goal of Kaizen Events was to identify and eliminate/reduce “the 7 deadly wastes”, establish one piece flow, staff the work-cell by takt time vs. cycle time analysis and sustain improvements through “5S” and visual management (standard vs. abnormality).• Led or facilitated 15 Kaizen Events saving $156K in direct labor, $273K WIP Inv and 844 ft2 floor space.• Created and taught Lean Curriculum to 350 multi-cultural shop floor associates using “The Socratic Method.”• Created 2004/2005 Tualatin Plant’s Lean Plan and successfully presented to GE’s Corporate CIO.

Boston, Ma, Us

• Led 47 union employees of Sheet Metal Department. • Improved sheet metal department deficiency by 15% through weekly counseling hourly associates on efficiency.• Reduced overdue orders by $50K (60%) by matching capacity to demand at bottleneck.• Reduced WIP inventory by $60K by minimizing queues at non-bottleneck operations.

Boston, Ma, Us

• Scoped out and implemented Defect Tracker in MRP II to give real time defect PPM and Pareto data.• Led bubble wrap packaging project reducing costs by $32K and transit damage defects by 75% (#2 on Pareto).• Redesigned direct pole (DP) contactor area layout to reduce labor by $30K and shop floor space by 30%.

Boston, Ma, Us

• Led MRP II implementation to improve productivity by $225K (4 positions and a $125K printer lease).• Initiated “DanBan” Project reducing Lead Time from 5 days to 1, finished goods inventory by $625K and VCP by $85K on flagship product line which had 100% market share but poor on time delivery to customers.• Implemented rotor inventory consignment for $100K reduction in raw inventory.

Boston, Ma, Us

• Led 23 non-union employees on the shaft fabrication line. • Implemented a cross-training process and tracking matrix for entire shop.• Learned how to run several critical machines personally to learn their capacity and improve employee relations.

Boston, Ma, Us

• Identified and evaluated several third party e-marketing consultants for all of Industrial Systems.• Researched and prioritized clean room fan filter unit market for growth opportunities.• Assisted in developing a three-year product plan and presented to GE Industrial Systems Technology Leadership.

Boston, Ma, Us

• Developed electrical design/specifications for Ford’s Retirement Home Electric Vehicle worth $5M in growth.• Developed electrical design/specifications for Yamaha’s Electric Airport Limousine worth $30K in growth.• Initiated and led component (Cover-Band) redesign productivity project for annual savings of $140K.

Boston, Ma, Us

• Project leader to design in-house fan boring process resulting in annual savings of $36K.• Led project to evaluate new braze alloy generating annual savings of $20K.• Seized opportunity to serve as 2nd Shift Production Supervisor during final five weeks of session.

Boston, Ma, Us

• Co-organized 1998 GE Supplier Day Convention. • Evaluated customer production part approval process (PPAP).• Guided potential suppliers through supplier selection process and co-created supplier selection handbook.