Gary Cockerham, Cpim Email & Phone Number

Remote

• Develop and implement lean conversion strategies with client partners in varying industries helping them to achieve rapid improvement and sustainable results.
• Lead client management and executive staff in creating and sustaining a kaizen culture.
• Facilitate kaizens and develop client partner Subject Matter Experts. Core tool competencies include: Standard Work, SMED, Material Flow and Kanban, Value Stream Mapping, Daily Visual Management, Policy/Strategy.

Newbury, Ohio

• Water Star is a wholly owned subsidiary of The Tennant Company with extensive R&D resources/capabilities. Products: mixed metal oxide anodes/cathodes, electrochemical cells.Provided operational leadership for 20.
• Improved revenue 148% through attainment of 28 new global customers resulting in first profitable year in 2014.* Led 2 successful new product launches, initially increasing revenue by $760K. Year 2 projection $1.6M.
• Relocated company from 14,000 sq. ft. facility in Newbury, OH to new build 30,000 sq. ft. facility in Parkman, OH.  Designed and contracted build of new HCL Etch System increasing capability and capacity.  Procured.
• Conducted EH&S safety blitzes providing awareness training, audit process, incentive programs resulting in delivery of company’s first year without an accident or injury in 2014, no Workman’s Compensation claims.
• Developed partnership with global distributor in Cathodic Protection and established new vertical market in E-Coat Systems increasing first year Sales by $350,000.
• Consolodated titanium material grades directly sourcing from mill, reducing price per pound 32%.

Orange, MA / Cranberry Township, PA / Czech Republic

• $2B public leading worldwide industrial company comprised of two strategic platforms in Process and Motion Control (PMC) and Water Management (WM), with approximately 7,400 employees globally. Reported to Senior.
• Generated and implemented new plant layout, using 3P, 5S, Standard Work and Variation Reduction Kaizen events, resulting in improved product flow, quality and productivity. Completed the relocation within.
• Conducted Kaizen events at Rodney Hunt, Fontaine, GA Industries, and JMA facilities (Czech Republic).
• Created and implemented on-line documentation system converting paper based ISO/Quality System to on-line quality management system with computer workstations in each cell and office.
• Delivered technology innovation by developing business case for obsolescing two thread-cutting machines and replacing with a thread-rolling machine for annual cost savings of $400,000.
• Developed strategy deployment deck for Rodney Hunt and facilitated monthly reviews.

Greater Milwaukee Area

• Directed lean and quality for 1,000,000 square foot facility with 745 associates producing gear drives, pinions, and large gears.
• Developed and implemented a Lean Tool Black Belt Certification program improving associate use of lean principles.
• Conducted an average of 6 Kaizen events per month with 27 associates earning Black Belt certificates in Lean Tools.
• Collaborated with educational consultant to develop Train-the-Trainer class to motivate and train associates in lean manufacturing principles for a higher rate of adaptation within the facility and improved productivity.
• Led project teams assigned to implement $23M plant modernization project.
• Led NPD stage gates 3 and 4 project teams to tool up and develop processes for new major product launch. Utilized 3-P Kaizen to design product and manufacturing to produce gear reduction drive units resulting in.

Stuarts Draft, VA

• Provided operational leadership for 135 associates including 12 direct reports, in a 100,000 square foot facility. Managed $43M P&L. Reported to Operations SVP.
• Developed plant culture where safety is owned and managed by associates resulting in plant maintaining perfect safety record for 3+ years.
• Drove improvements in delivery to 95%+, sustained for 3 years with 6 months straight at 98%.
• Drove improvements in quality, using Kaizen achieving 5 Sigma levels plant wide.
• Used TPM Kaizen to build a robust, proactive, preventive maintenance program improving machine uptime.
• Maintained rigid Kaizen schedule averaging 4 events monthly with an associate transition from 135 to 80 associates resulting in efficiency improvements handled through attrition over 4-year period with sales moving.

Kinston, NC

• Provided plant management for a 165,000 square foot facility with 123 associates generating $48M annually. Reported to Operations SVP.
• Drove on-time delivery to customer request date from 47% in 2002 to 98% in 2004.
• Improved inventory turns from 8.2 in 2002 to 13.4 by February 2005.
• Drove successful lean conversion, of the facility improving productivity by 66% from 2002 to 2005.
• Drove 50% year-over-year improvement in quality, as measured in parts per million (PPM).
• Managed 3 successful new product launches in Gilbarco’s Kinston facility and Veeder-Root facility in Sao Paulo, Brazil.

Greensboro, NC

* Provided Engineering support to regional remanufacturing centers in Dallas, Chicago, & Hayward* Developed and implemented World Class on-line documentation system for ISO registration* Consolidated Remanufacturing operations in Dallas and closed the other 2 centers* Project lead to relocate Dallas operations to Kinston, NC.During my Engineering years.

Greensboro, NC

* Marketing and Engineering support for 3 regional remanufacturing centers.* Developed and expanded export market for remanufactured products. Grew export business from 0 to 22% of total revenue generated by remanufactured products ($30M). Developed market for remanufactured products in South America.* Spent 65% of my time on Strategic and Marketing duties.

Greensboro, NC

* Managed a team of 7 Industrial and Manufacturing Engineers* Implemented Cellular Manufacturing and JIT Production concepts* Handled new product introductions and Engineering changes* Attended classes conducted by W.E. Deming

Greensboro, NC

* Developed and implemented new layout for the Assembly Focused Factory incorporating JIT principles.* Established first assembly cell, in the Greensboro facility, based on JIT concept.

Greensboro, NC

* Trained and certified in the application of M.O.S.T. by Maynard Institutes* Performed methods analysis, time studies, ratio delay studies and router maintenance* Created new work area layouts and work management manuals, SOPs* Trained, internally, to perform Job Classification in a union environment

Greensboro, NC

* Supervised 62 bargaining unit associates assembling gasoline pumps and dispensers* Improved productivity by 30%* Reduced overtime by 25%* Drove First Pass Yield from 55% to 98 %* Read and learned about the application of M.O.S.T. (time study)