Dave Schaefer Email & Phone Number

Mansfield, Oh, Us

Mansfield, Oh, Us

Mansfield, Ohio, United States

Perrysville, Ohio, United States

Lead team of 25 reports (23 technicians, 1 supervisor, and 1 purchasing clerk) in overseeing maintenance activities for 700,000 sq. ft. of production facility and warehousing space. Manage $700,000 maintenance and $1.2 million capital improvement budgets. Develop and implement plant wide maintenance strategy in alignment with business plan, focusing on overall equipment effectiveness (OEE). Launch and manage project and continuous improvement initiatives. Review activities with supervisors and production department managers daily.* Slashed downtime 32%, maintenance spending budget 37%, and labor hours 36% by defining expectations, providing frequent feedback on goal status, collaborating with other divisions to maximize buying power, and creating environment of continuous improvement and accountability.* Co-implemented software-based planned maintenance program that produced more efficient management of OEE, PM, technician utilization, work orders, and part inventory, establishing foundational processes established as best practices that transformed entire company. Facilitated expansion of cloud-based control system for universal remote monitoring from 2 to 10 systems, allowing for increased trend analysis, faster corrective actions execution, continuous improvements.* Reduced YoY technician labor variance from 25% to 3% and YoY budget variance from 40% to 2%, while maintaining on-time project completion, including robot replacement project critical to produce 78% reduction in downtime for production line.* Implemented controls on spending and labor hours, while simultaneously improving effectiveness and reducing call-backs by 20%.* Initiated technician training program that provided instruction on root cause analysis, electrical and mechanical theory, and OHSA code compliance.* Oversaw capital expenditure projects that included Fanuc robot upgrade ($75,000) and custom PLC based equipment ($100,000).

Perrysville, Ohio

Managed 6 reports (1 supervisor and 5 technicians) in leading Quality Department of only American-owned manufacturer of vitreous china products. Drove culture of quality throughout organization. Translated needs of customers into measurable quality expectations throughout supply chain and manufacturing process. Conducted daily activity reviews with supervisor and production department managers.* Developed and implemented plant-wide QS-9000 quality system with simplified phase-gate process, designed to reduce customer claims, increase first run yield (RTY), and minimize cost of poor quality.* Achieved highest recorded external customer quality satisfaction rating (spanning 10 years). Reduced claimed defective pieces by 51%, increased external quality sigma score from 4.35 to 4.48, and slashed annual cost of external poor quality by 65%. Doubled internal auditing coverage, implemented risk-specific products sampling plan, developed validation/verification testing plans, and implemented new SPC controls and corrective actions. Re-instituted regular VoC feedback schedules.* Successfully managed parent company’s field quality issue by inspecting over 35,000 toilets, using teams consisting of individuals from 3 countries. Contained 100% of suspect product with zero new field issues.* Managed North American warranty claims process; reduced annual claims by 10%.

Big Prairie, Ohio

Served as engineer for New Product Development and legacy trim products. Conducted daily reviews of production schedule and issues involving 12 injection molding machines and PLC-based hydraulic and pneumatic custom processing equipment for 100,000 sq. ft. facility. Managed 38 reports across Engineering, Molding, Assembly, Tool Room, and Maintenance departments, with accountability for $2 million P&L for Plastics Division.Provided engineering management support to Sanitaryware Engineering team and production. Analyzed operations, procurement, logistics, sales, accounting, quality, maintenance, IT, administrative support. Conducted performance reviews.* Exceeded target profit contributions each year for Plastics Division.* Achieved 100% on-time delivery to parent plant, with 99.9% field customer satisfaction.* Implemented Kanban system credited with reducing inventory dollars by 6%.* Conducted injection cycle time optimization studies, leading to 7% reduction in molded costs.* Re-sourced equivalent plastic resin, slashing raw materials costs by 12%.* Led re-design of new product which launch was on hold and causing idleness of $500,000 in tooling and $300,000 in press. Modified 6 injection molds and rubber diaphragm using extensive CAD modeling and DFMEA work. Successfully met product performance specifications.* Directed all aspect of facility closure process, which involved inventory build-up, product transfer, asset relocation/sell off, real estate disposal, property auction, and human resource activities. Completed closure project on schedule and within budget, with 100% placement for laid off employees.* Member of union contract negotiation team.* Oversaw capital projects that included 170-ton Cincinnati Milacron injection molding presses ($150,000) and 3 PLC-based verification/validation test stands ($50,000).

Mansfield, Ohio

Led team of engineers in development and launch of innovative mechanical-pneumatic industrial pumps and electro-mechanical fluid handling accessories from design concept to production. Functioned as project manager for all new product releases, leading business-wide, cross-functional teams. Developed production assembly cell and new supplier base.* Led team in innovating new electro-mechanical air savings device for AODD pumps. Increased pump efficiency up to 55% while increasing fluid flow by 15%, winning several industry awards, including Pump & Pump Systems Product Innovation of the Year, Pump Industry Awards Product Technical Innovation of the Year (finalist), Frost & Sullivan New Product Innovation Award, and IDEX Innovation Product of the Year.* Led international team of product engineers and designers in developing innovative mechanical air savings device for AODD pumps (patent pending) that reduced product cost by 55% over previous design, along with increasing pump efficiency 35% and fluid flow 5%. Experienced high market acceptance due to lower entry price point and low field expertise requirement for servicing.* Implemented and owned phase-gate development process.* Spearheaded several production process improvement projects that improved efficiency, accuracy, and throughput.* Led various VoC initiatives.

Lexington, Ohio

Managed cross-functional product team in developing pressure sensors and switches, transmission position switches, and temperature sensors and switches, with accountability for $4.9 million in capital.* Designed innovative electro-mechanical bimetal over-temperature switch used on automotive transmissions that captured bimetal disc to withstand harsh environmental temperatures and vibrations (patent pending). Rapid proto-typed design iterations to evaluate various solutions, expediting design cycle to meet customer’s aggressive project timeline. Allowed for risk-specific verification testing, meeting customer’s stringent performance requirements. Produced 75,000 estimated annual units (EAU), with 400,000 in annual sales potential.* Owned division’s phase-gate process and ensured effective utilization of Black Belt in for Six Sigma tools.Senior Project Engineer (April 1999-February 2002)Supervisor of Pressure Products Product Development Team. Consisted of three Product Engineers and three Product Engineer Technicians. The team was responsible for $43M annual revenue. Primary interface with automotive customers regarding new applications and existing program support. Coordinated and tracked activities with internal departments, suppliers, and customers to meet Team objectives. Designed advanced electro-mechanical pressure sensors and switchesProduct Engineer (October 1992-April 1999)Directed efforts of multiple Product Engineer Technicians. Designed advanced electro-mechanical pressure sensors, multi-function thermistor temperature sensors, and bimetallic disc temperature switches for automated, high production automotive market. Served as Team Leader for new developments from conception through initial full volume, ensuring both internal & external customer expectations are met or exceeded. Provided Root Cause analysis for many different types of production related problems. Leader and member of cross-functional product and QS-9000 implementation teams.