Dave Whaley Email and Phone Number

VELOCITY, FOCUS and LEVERAGE

Foundry and Lean Sigma leadership in casting and finished machining of ferrous and non-ferrous alloys utilizing green sand, no-bake and vertical spun casting processes.

Managing Partner of Lean Sigma TOC implementation firm. We also fill interim manufacturing operational assignments for our clients in times of stress and need. Throughput improvement, cash liberation and profit improvement with no investment create the CIS mark of excellence.Visit our website at www.continuousimprovementstrategiesllc.com

Managed P&L of business activities and general management of 5 manufacturing plants in AL-FL-SC-GA-AR, manufacturing, fabricating and assembling Class 7 and 8 Dump Bodies for national and international OEM and dealer marketing channels. Integrated several companies and brands into single largest industry leader with $200+M in sales.Corporate Director Lean and CI (Initial assignment first 5 months)Established and developed Lean/continuous improvement strategy, deployment and implementation plan for 10-plant North American footprint

Managed P&L and operations functions for Tier I automotive parts plant (aluminum foundry and machining) (pistons) achieving an annual revenue of $100M with an employee base of 400 employeesRestructured plant and management teams; facilities included a cast aluminum foundry, high speed CNC machining, assembly, product design/ testing and distribution centerLed the successful implementation of TS 16949 as Quality business system modelDeveloped and implemented an improvement plan to improve business base and improve plant metrics to Best-In-Class benchmark standards applying Lean Sigma and TPS deployment methodologiesKey Accomplishments:Successfully obtained 100% on-time delivery of productsPlayed leadership role in overseeing plant turnaround from -2% margin in 1998 to +35% in 2004 Improved inventory turns from 21 to 107 by supply chain redesign.Facilitated a significant reduction in defective product in customer from 2500 to 9 PPM EARLIER CAREER

Responsible for global quality and productivity improvement for $1.3B polyurethane foam producer with 43 plant global footprint. Achieved largest North American ISO/QS 9000 simultaneous certification at all company locations in 1996-1997.

VP and COO of multi-plant group of sintered powder metal firm based in Germantown, WI. Key strategic supplier to GM, Ford, Chrysler and Honda. Strategic mission was preparation of company for IPO or sale.

Group Director of North American Manufacturing for 4 plastic extrusion and machining plants that served global metal replacement market.

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