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Manufacturing Operations Leader with over 20 years of international leadership experience managing plant and multi-site operations paired with an engineering background. Performance turnaround and cultural change leader through people, process, and Lean Manufacturing methodology (Toyota Production System). Proven track record building high-performing teams and generating outstanding KPI results across multiple industries - automotive, clean energy technology (PV solar, EV), glass, and IT (high-growth startups to Fortune 500).Key Skills:• MANUFACTURING OPERATIONS MANAGEMENT - Strategy, Planning, Execution, Systems, Process, Safety, Quality, Delivery, Cost (SQDC), Production, Assembly, Engineering, Maintenance, IT, Customer Service, Supply Chain, Project Management, SOX Compliance, TS 16949, ISO 14001, ISO 9001, Efficiency, Productivity, Profitability• LEAN MANUFACTURING - Toyota Production System (TPS) working with Toyota WCM, TPM, Continuous Improvement, Process Improvement, Kaizen, 5S, SOP, Visualization, Standardization, PDCA, Problem Solving, RCA, TOC• LEADERSHIP - Influencing, Coaching, Mentoring, Developing, Team Building, Communication, Empowerment, Engagement, Inclusion, Collaboration, Relationships, Cultural Change, Ownership, Accountability • SUPPLY CHAIN - Supplier Management, Quality, Delivery, Capacity, Constraint, Cost, Risk, Procurement, Localization; APQP, PPAP, VOC• IT / AUTOMATION – ITIL v3 certified, Software Application Development (Agile Scrum Master), Manufacturing Execution Systems (MES), Controls Engineering • GLASS – Subject Matter Expert Glass Bending, Tempering, Processing. 10+ years.KEY ACCOMPLISHMENTS• Led TPS Lean Manufacturing performance cultural turnarounds of four automotive plants to world-class benchmark KPIs• Transformed worst performing plant to global best benchmark out of 31 plants. Generated $22M increase in annual operating profit. Won $30M new business. Delivered $3M in labor savings.• Led, built, and scaled global manufacturing automations group. Started up five greenfield plants. Scaled from six to 36 production lines. Improved manufacturing systems uptime to 99.97%. Eliminated top customer complaints. Innovated process validation systems.
Korn Ferry
View- Website:
- kornferry.com
- Employees:
- 19113
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Korn FerryCharleston, Sc, Us
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Practice Director, Manufacturing OperationsKorn Ferry Oct 2022 - PresentLos Angeles, Ca, UsManage interim manufacturing operations leadership and subject matter expert role execution delivering pivotal performance transformations, key operational improvements, assessments and coaching, cultural change, capital expansions, and scaling at industry-leading Fortune 500, Private Equity, and Private clients. Our coverage spans a spectrum of industrial manufacturing sectors, notably automotive, green energy, building products, and heavy machinery with leadership expertise in production, assembly, quality, engineering, maintenance, and supply chain. In addition to personally performing select interim manufacturing operations leadership roles, my responsibilities include vetting, leading, and coaching interim executives and professionals, client engagement management, project management, and partnering with Managing Directors on business development. Examples of roles personally executed include:* INTERIM DIRECTOR, OPERATIONS - Private Equity owned Building Products manufacturer - Responsible for three plants, $350M revenue, 800+ people. Increased output 23%, reduced customer order backlog 30%, 0 SIR, restructured and aligned leadership team, (Reported to COO)* INTERIM MANUFACTURING LEADER - Private Tier 1 automotive / off-road vehicle manufacturer and assembler – Responsible for three plants, $250M revenue, 600+ people. Increased production output 18%, reduced customer order backlog 42%, 0 SIR, coached and aligned leadership and production teams through Lean methodology (Reported to Owner)* INTERIM OPERATIONS LEADER – Fortune 100 Construction and Agriculture OEM - Led critical turnaround intervention of Tier 1 private supplier for OEM - Responsible for two plants, $27M revenue, 135 people. Increased supplier output 51%, stopped missed deliveries, prevented OEM production shutdown, achieved quality KPIs and 0 SIR (Reported to OEM global Supplier Chain Leader)
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Senior Consultant, Manufacturing Operations (Patina - Korn Ferry)Korn Ferry Jun 2018 - Oct 2022Los Angeles, Ca, UsExecuted interim senior leadership roles and led manufacturing performance turnarounds for Fortune 500 OEMs, private equity, and private clients at Patina (acquired by Korn Ferry). Assessed current state, defined desired state, developed improvement strategy and gap closure plan, coached/aligned/recruited leadership, executed solutions (SQDC, throughput/output, bottlenecks, profit).
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Director Of Operations | Manufacturing ConsultantDp Consulting | Apex Management Consulting Sep 2013 - PresentExecute interim manufacturing and operations leadership roles and performance turnarounds within automotive, green energy, off-highway vehicles, building products, glass, and industrial manufacturing. Skilled across production, assembly, quality, safety, engineering, maintenance, supplier management, supply chain, and IT management (MES, automation, Scrum Master, Agile software development, ITIL IT service management).Lead manufacturing operations transformations, leadership, constraint supplier management and performance improvement, and leadership assessments and coaching. Assess, develop, and implement strategy, planning, and execution solutions to improve and scale operations, manufacturing, safety, quality, cost, delivery, efficiency, throughput and customer value through TPS Lean methodology. Manage agile scrum software application development projects.
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Director Of Operations, CooI-Command, Ltd. Nov 2013 - Dec 2015Scottsdale, Az, UsLed business operations strategy and execution for a human-to-machine IT startup under consulting contract. Developed and directed business systems, processes, and services to enable growth, scalability, and collaboration. Managed project management, agile software development contract manufacturing and quality. • Established US HQ operations: project management, manufacturing services, quality, IT, HR, accounting, legal, facilities • Developed scalable key business operational systems, processes, and reporting• Implemented cloud based operational systems (CRM, Finance/Accounting, Customer Service, Project Management, Document Management, Collaboration tools)• Created ISO 9001:2008 compliant enterprise Quality Management System (QMS) -
Senior Manager, Bas Enterprise TechnologyFirst Solar Sep 2012 - Jun 2013Tempe, Arizona, UsDirected global business applications development, delivery, and support for operational custom enterprise platforms and SAP enhancements (ABAP). Managed onshore and offshore FTEs, consultants, and vendors. • Delivered $9M in annual business process improvement savings• Deployed global shared service development model and led offshore vendor management• Achieved 66% reduction in development cost • Developed people and processes to improve operational efficiency, effectiveness, quality, morale, and value delivery -
Operations Manager, Manufacturing Execution Systems (Mes)First Solar Dec 2007 - Sep 2012Tempe, Arizona, UsBuilt, led and scaled 24/7 MES manufacturing automation operations (people, processes, systems, new plant start ups) through 6x growth to 36 manufacturing lines globally. Led 24/7 global support of automation applications and controls engineering, MES SQCD continuous improvement solutions development, deployment, change management, and plant MES replications. Supervised 10 direct reports and 25 dotted-line salaried staff. • Started up 5 new manufacturing plants on-time, on budget (US, Germany, Malaysia)• Improved system availability to 99.97%, increasing output by over 360k units ($45M revenue)• Eliminated main customer complaints by innovating process and product validation systems • Built global renowned A-player team - recruited, coached, mentored, developed, and promoted• Implemented global module process improvements for quality, efficiency, throughput, and cost • Developed global Service Level Agreements (SLAs), KPIs, 24/7 on-call system, knowledge base, automated manufacturing process monitoring• Directed MES IT service management (ITSM): Incident/Problem/Change/Release/Knowledge Management • Led global problem management (process owner) – defined process, launched application, trained 200 people
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Director Of OperationsMaclellan Integrated Services, Apr 2007 - Nov 2007Lexington, Kentucky, UsDirected operations and customer service spanning 12 manufacturing services sites across automotive OEMs in the US and Canada. Supervised four direct managerial reports, 30 indirect salaried supervisory staff, and 265 indirect hourly employees and contractors. • Launched and expanded new site operations at Toyota CAPTIN plant • Restructured management team, led cultural change and developed key leadership • Improved NUMMI site quality and customer satisfaction -
Manufacturing Operations ManagerPilkington Apr 2006 - Apr 2007Lancashire, England, GbDirected site-wide manufacturing and assembly operations for a Tier 1 automotive glass manufacturing plant producing eight million products annually. Spearheaded advanced quality activities with Toyota, Honda, and Subaru supporting on-time NPI and customer satisfaction. Led corporate liaison to Toyota BAMA. Supervised 320+ associates (five direct managerial reports, 15 indirect, and 300 hourly associates).• Generated $22M increase in operating profit • Increased plant production capacity by 29% via lean TPS productivity improvements • Enabled sales growth of 1.8M units by reducing unit cost by > 30%• Improved safety 77%, quality 78%, yield 80 basis points, uptime 70 basis points, throughput 29%, • Achieved 100% on-time delivery• Delivered $3M annual labor savings - eliminated 63 positions without layoffs through benchmarking• Achieved site TS16949 certification• Personally awarded Pilkington’s President’s Excellence Award - 2006 -
Plant Tempering ManagerPilkington Dec 2002 - Mar 2006Lancashire, England, GbLed Tier 1 automotive glass manufacturing operations for tempering, value added assembly, and tooling departments. Produced over six million products annually. Supervised four direct managerial reports, nine indirect salaried, 215 hourly associates.• Improved safety 75%, quality 70%, yield 70 basis points, and uptime 60 basis points• Achieved 100% on-time delivery• Led globally replicated pilot project delivering product throughput increases of 21% - 41%• Executed advanced quality activities, customer quality and NPI liaison / • A-Level corporate liaison to Toyota BAMA • Achieved site ISO 14001 certification• Personally awarded Pilkington’s President’s Excellence Award - 2005
Daniel Payne Skills
Daniel Payne Education Details
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The University Of ToledoMechanical Engineering -
Apesma / Deakin University (Australia)Technology Management
Frequently Asked Questions about Daniel Payne
What company does Daniel Payne work for?
Daniel Payne works for Korn Ferry
What is Daniel Payne's role at the current company?
Daniel Payne's current role is Manufacturing Operations Leader | Operations Director | Transformational Leadership | Manufacturing Consultant.
What is Daniel Payne's email address?
Daniel Payne's email address is da****@****lar.com
What is Daniel Payne's direct phone number?
Daniel Payne's direct phone number is +148069*****
What schools did Daniel Payne attend?
Daniel Payne attended The University Of Toledo, Apesma / Deakin University (Australia).
What skills is Daniel Payne known for?
Daniel Payne has skills like Continuous Improvement, Process Improvement, Manufacturing, Lean Manufacturing, Management, Operations Management, Program Management, Change Management, Team Building, Project Management, Product Development, Start Ups.
Who are Daniel Payne's colleagues?
Daniel Payne's colleagues are Pakkaporn Amnajthalerngsak, Manoj Rao, Natalie Stein, Gail Lumby, Alena Ježková, Greg Barnes, Kiera Gilbert.
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