Gary Ballard Email and Phone Number
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Educational background includes a MS degree from University of Tennessee in Engineering Management, BS from ETSU and AAS from PSTCC both in Industrial Engineering with manufacturing and mechanical concentrations. I have over 24 years experience in lean principles components manufacturing and over 18 years experience as a Manufacturing Engineer. This includes roles as a Senior Manufacturing Engineer (over 12 years) and Quality Engineering Manager (2 years). These engineering roles included functional department leadership or direct responsibility for manufacturing equipment justification, purchase, design and installation. Responsible project amounts over $30M over a twelve-year period for "spot" installs and over $50M over a recent four year period for new technology. All projects performed in a LEAN Toyota Production System (TPS) automotive component manufacturing Tier 1 facility.Manufacturing Engineer job role has given me an innate knowledge of manufacturing systems, equipment, controls, automation, metal cutting, steel heat-treatment, CNC, PLC programming, robotics, welding, friction welding, electrical & electronic sub systems and mechanical design (machines, automation, jigs & fixtures). Many manufacturing design projects can be credited to my past experience.Quality Engineering/Assurance Manager leadership role promoted the use of LEAN manufacturing to include Design for Manufacture (DFM, VA/VE, FMEA process), supplier development (APQP & PPAP), GAP analysis, capability study, process solving/corrective actions (Root Cause Analysis), Value Stream Mapping (VSM), continuous improvement facilitation (Kaizen) and personnel development of a highly skilled quality assurance team. Key job focus has been to be a LEAN practitioner in all career roles.
Fresenius Medical Care North America
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Sr. Manufacturing EngineerFresenius Medical Care North America Apr 2018 - PresentBad Homburg, Frankfurt, DeCurrent job purpose and scope is to ensure that all manufacturing related aspects of the company products are addressed throughout the product development cycle. The position works closely with engineering team, R&D, quality, and operations to support the manufacturing of current and next generation renal healthcare products. Target is to continuously improve manufacturing processes and site operations to include expansion of facilities and introduction of new technology. LEAN GMP practices is the overriding methodology of all we will do in execution of current 10 year expansion plan.
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Production EngineerJtekt Automotive Tennessee-Vonore, Inc. Jun 2014 - Mar 2018Job role as Production Engineer (PEPD) had corporate level responsibility for the design of manufacturing processes for hydraulic and electronic automotive steering and driveline components. Expert technical level job role with direct responsibility for multiple facilities including supplier support (i.e. materials,machinery & processing), production planning, justification, process design, layout, procurement, runoff validation, installation and launch of manufacturing processes. Role is a direct key contributing member of a corporate level engineering team responsible for over $375M+ budgeted manufacturing & process changes for the next five fiscal years.
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Quality Assurance/Quality Engineering ManagerThe Babcock & Wilcox Company Aug 2012 - May 2014Quality Engineering Manager role was responsible for the process development, verification, validation and continual improvement of high-precision manufacturing & processing for products supporting the nuclear fuel industry. This occurred in an ASME NQA-1 QMS controlled high volume production environment with over $400M+ annual projected revenue. This leadership role was responsible for development and guidance of a highly skilled quality assurance team of fourteen (14) direct reports. Other key responsibilities include assessment of employee development; providing positive and constructive feedback; conflict resolution and performing annual performance reviews. Manufacturing performance issues are addressed with corrective actions (CAPA) utilizing performance improvement plans or disciplinary actions (supplier compliance). Manager serves in a role as facilitator for QA personnel development so that they become product and process experts in their knowledge areas and can serve as a source of expertise for manufacturing technicians. Manager also certifies the quality of the products produced (Chain-of-Custody - COC), through implementing Quality and Inspection Plans and continually collaborating to improve the strategies be more robust. Manager ensures corrective and preventive actions that result from Material Review Board (MRB), quality issues, or audits are implemented in a timely manner. Manager communicates company business and organizational goals; mission and values to the team and creates planning for them to be integrated within team and personal goals, objectives, and work tasks. All tasks performed while applying lean methods to processes and procedures to eliminate waste while defining, measuring, and improving process efficiency.
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Principle Manufacturing/Process EngineerThe Babcock & Wilcox Company Aug 2008 - Aug 2012Job role responsible for the support and continual improvement of high precision machining processes making components for nuclear fuel processing equipment. Job performed in a classified and secured facility running a lean production system. Tasks included responsibility for manufacturing equipment justification, qualification for production and continual process improvement to increase efficiency and reduce waste. Process development included support of machine, fixture and tool design, process documentation and part quality dispositions (NQA-1 nonconformance evaluations). Job required close working relationships and communication with highly skilled machinists, CNC programmers, production and procurement personnel. Support of the supply chain team, on-site supplier manufacturing capabilities evaluations (audits) and job bid proposals were other job tasks. Job also required leadership/technical support role in the operations of an offsite startup company expansion (NASA machine shop) directing machinist with initial annual revenue of $500,000 and $50M+ projected annually.
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Sr. Manufacturing EngineerJtekt Automotive Tennessee-Vonore, Inc. Mar 2003 - Aug 2008Job role (senior manufacturing engineer) with leadership and mentoring task additional to manufacturing engineering responsibilities including technical support for all rack bar product machining areas of the manufacturing facility. Role includes research, design and development of new technology, manufacturing processes and machinery. Technical liaisons (mentors) are senior manufacturing engineers and provide technical assistance, support and training to all manufacturing engineers without direct report responsibilities.
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Manufacturing EngineerJtekt Automotive Tennessee-Vonore, Inc. Mar 1996 - Mar 2003Job role responsible for the development, procurement, setup, launch, support and continual improvement of precision machining processes for automotive steering gear components. Job performed in a Tier 1, QS-9000 qualified facility running a modified Toyota Production System. Tasks included direct responsibility for lean manufacturing equipment justification, purchase, qualification and installation amounting over $30M+ over an eleven-year period. Machine and process development included machine, fixture and jig design and verification. Automotive components were supplied JIT to major Japanese based automotive manufacturers utilizing Toyota Production System concepts.
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Maintenance TechnicianJtekt Automotive Tennessee-Vonore, Inc. Apr 1993 - Mar 1996Job role responsible for the installation, setup, troubleshooting, and repair of electrical, hydraulic, pneumatic and mechanical plant processes. This machinery included highly automated machining, production and assembly equipment. Assumed Team Leader (leadership) role as required which was responsible for directing four maintenance technicians.
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Team Leader / Production TechnicianJtekt Automotive Tennessee-Vonore, Inc. Mar 1989 - Apr 1993Leadership role responsible for directing a work cell consisting of three machining lines and fifteen technicians producing eleven different automotive steering components. Training included many aspects of "Front-line Leadership" and a four-week OJT session in Japan in both assembly, machining and lean manufacturing (Toyota Production System - TPS) procedures for one month.
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Maintenance TechnicianGemtron Corporation Dec 1985 - Feb 1989Job role responsible for the assistance and support of the Plant Engineer and production support; including the installation, setup, troubleshooting and repair of industrial electrical and mechanical production systems. Direct responsible for setup, programming and operator training of CNC water jet cutting equipment.
Gary Ballard Skills
Gary Ballard Education Details
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University Of Tennessee, KnoxvilleIndustrial And Systems Engineering -
East Tennessee State UniversityIndustrial Engineering: Manufacturing & Mechanical Design
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Pellissippi State Community CollegeMechanical Engineering Technology; Manufacturing And Mechanical (Design) Options
Frequently Asked Questions about Gary Ballard
What company does Gary Ballard work for?
Gary Ballard works for Fresenius Medical Care North America
What is Gary Ballard's role at the current company?
Gary Ballard's current role is Sr. Manufacturing Engineer at Fresenius Medical Care North America.
What is Gary Ballard's email address?
Gary Ballard's email address is ga****@****ter.net
What is Gary Ballard's direct phone number?
Gary Ballard's direct phone number is +142380*****
What schools did Gary Ballard attend?
Gary Ballard attended University Of Tennessee, Knoxville, East Tennessee State University, Pellissippi State Community College.
What are some of Gary Ballard's interests?
Gary Ballard has interest in Animal Welfare, Science And Technology.
What skills is Gary Ballard known for?
Gary Ballard has skills like Lean Manufacturing, Manufacturing Engineering, Continuous Improvement, Manufacturing, Fmea, Kaizen, Six Sigma, Spc, Machining, Engineering, Value Stream Mapping, Ppap.
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