Greg Esper, P.E. Email & Phone Number

Ann Arbor, Mi, Us

Ann Arbor, Mi, Us

An expert in Manufacturing Process Management, Lean Implementation and Engineering Systems. Working directly from the strategic and operational objectives of the C-Suite, considering the entire business and designing implementation plans that help clients reach their objectives for Safety, Quality, Productivity and Profitability. Forging strong cross functional teams to achieve quantifiable and sustainable results. Visual Factory implementation.Personnel development – both within the… Show more An expert in Manufacturing Process Management, Lean Implementation and Engineering Systems. Working directly from the strategic and operational objectives of the C-Suite, considering the entire business and designing implementation plans that help clients reach their objectives for Safety, Quality, Productivity and Profitability. Forging strong cross functional teams to achieve quantifiable and sustainable results. Visual Factory implementation.Personnel development – both within the consulting firm and with clients. One on one coaching and mentoring. Shingo model of alignment between personal and organizational goals.Implementing Lean Product Development with a $2B Division of a leading Oil Well Services Company. By following the principles of Toyota Lean PD, we have initiated a complete organizational re-structure and cultural transformation to cut development time in half by simplifying the way the organization works and promoting collaboration. We have so far achieved over $90M EBITDA.Leading the North American practice for VAVE. Developing VAVE structure and training personnel in organizations, concurrent with facilitating VAVE workshops. Currently working in the Oil & Gas sector. My last project had an average 32% cost reduction leading to over $40 million additional EBITDA in 20 product groups. The previous project realized 43% cost reduction leading to $6.4 million annually for a single product line. The initial (pilot) project completed 20 workshops in 6 months, with an average savings of 26% and $11.8 million annually. A strategic restructuring of the client’s product portfolio allowed us to achieve a 10x effectiveness in subsequent workshops. Show less

A few examples of key clients and accomplishments:• The leading US Designer and manufacturer of industrial fiberglass doors – Private Company• Implemented Lean Kaizen and Quality management system• Reduced 6-month backlog to 2 weeks in first 5 months• QC Rejects reduced from 15% to ZERO – virtually eliminated over 2 months• $12B Class 1 freight railroad Heavy Rebuild Shop• Implemented Shingo Model Center of Excellence• Implemented Quality system for root cause… Show more A few examples of key clients and accomplishments:• The leading US Designer and manufacturer of industrial fiberglass doors – Private Company• Implemented Lean Kaizen and Quality management system• Reduced 6-month backlog to 2 weeks in first 5 months• QC Rejects reduced from 15% to ZERO – virtually eliminated over 2 months• $12B Class 1 freight railroad Heavy Rebuild Shop• Implemented Shingo Model Center of Excellence• Implemented Quality system for root cause analysis and corrective action for locomotive failures – developed Quality Playbook• Developed Locomotive rebuild program - APQP• North America’s leading supplier of transportation seating and safety solutions – Family owned Private Company• Implemented Lean Production system to eliminate customer backlog and reduce order time from 6 months to 3 weeks• The leading manufacturer of wire and cable solutions in the world - $6B• Implemented Visual Management and Lean Production System• cut changeover times in half• increased EBITDA from -3% to +7% in 4 months• $30M Manufacturer of Hydraulic and Electric, Worm Gear and Planetary Gear Winches and Planetary Hoists• Implemented Kan Ban system• Increased inventory turns from 2 to 7 in less than 2 months Show less

Farmington Hills, Mi

Director of Quality – North AmericaReports to Vice President of Quality. Responsible for staff and KPIs at 8 plants and 2 labs, as well as a corporate staff (57 direct, 4 matrix). Primary responsibilities include setting up key measurable reporting system (safety, quality/delivery, financial/operational), managing customer concerns/problem solving, leading improvement initiatives, managing new product development/Advanced Product Quality Planning (APQP) and personnel… Show more Director of Quality – North AmericaReports to Vice President of Quality. Responsible for staff and KPIs at 8 plants and 2 labs, as well as a corporate staff (57 direct, 4 matrix). Primary responsibilities include setting up key measurable reporting system (safety, quality/delivery, financial/operational), managing customer concerns/problem solving, leading improvement initiatives, managing new product development/Advanced Product Quality Planning (APQP) and personnel development.Major accomplishments:• Established Dashboard (Quality Operation System/QOS or Key Metrics) system at all NA plants.• Started Obeya room activities at all plants.• Initiated Problem Solving training and activities to reduce repeat customer concerns. Repeat concerns reduced by 50% in first 3 months. The organization now has a structured approach to effectively and efficiently solve problems.• Performed Design of Experiments (DOE) to develop ideal process parameters for a successful rubber coating process, salvaging a $3 million new product launch. Several other DOEs were initiated for additional problem solving efforts.• Personal development of staff, including turnaround of a failing Plant Quality Manager, and professional certification (CQE) of 6 staff members in first 6 months. Show less

Ann Arbor, Mi

Consulting business that defines strategic direction with Service and Manufacturing companies, then implements and transforms their business with change. Director, Ann Arbor OfficeReports to Chief Operating Officer. Manages staff of full-time and contract quality professionals for all consulting engagements for the office. Acts as Consultant/Trainer on Lean/Six Sigma (Master Black Belt), ISO/TS16949, ISO 9000, ISO14001, OHSAS 18001, Lean Transformation including The Toyota… Show more Consulting business that defines strategic direction with Service and Manufacturing companies, then implements and transforms their business with change. Director, Ann Arbor OfficeReports to Chief Operating Officer. Manages staff of full-time and contract quality professionals for all consulting engagements for the office. Acts as Consultant/Trainer on Lean/Six Sigma (Master Black Belt), ISO/TS16949, ISO 9000, ISO14001, OHSAS 18001, Lean Transformation including The Toyota Production System, 5S implementation and auditing, Kaizen, and Kanban. Subject Matter expert in all automotive Quality Management disciplines including APQP, TQM, QOS, DOE, problem solving, SPC, MSA, Q1, PPAP, among others.Major accomplishments:• 50+ Audits• Millions $ savings for clients through Six Sigma Black Belt projects• Developed and led LEAN training for AIAG (Automotive Industry Action Group)• Delivered training and consulting services domestically and in major international markets, primarily to senior and executive management groups, in the strategic implementation of integrated management systems incorporating ISO 9001, QOS/BOS, New Product Development (NPD) and Launch, and Lean Enterprise systems in rational, profit oriented solutions.• Acted as a change agent within clients to create the culture required to focus on process improvement to create value for customers and stakeholders.• Developed and implemented turnaround complete business strategies for many critical suppliers for Daimler Chrysler and Visteon Corporation, as part of a Third Party Supplier Development Process created for these two key clients. As an example, in one case a critical business process was reduced from one year to 30 days using Lean techniques.• Implemented Quality Management Systems integrated with Lean/Six sigma methodology with multinational manufacturing companies.• Developed a guaranteed and proven success ISO/TS implementation process. Show less

Dearborn, Mi

Program Manager, Chassis Systems, 2000 - 2003Reported to Director of Chassis Engineering and to Chief Engineer. Managed professional staff and new product development process including quality planning, verification, validation, and quality and reliability. Responsible for new product and content development including engineering design, manufacturing, and quality.Major accomplishments:• Developed and implemented from concept to launch (including business case development and… Show more Program Manager, Chassis Systems, 2000 - 2003Reported to Director of Chassis Engineering and to Chief Engineer. Managed professional staff and new product development process including quality planning, verification, validation, and quality and reliability. Responsible for new product and content development including engineering design, manufacturing, and quality.Major accomplishments:• Developed and implemented from concept to launch (including business case development and presentation to senior management) key new technology that created a new competitive position in the market place. This product alone had a $4 million development budget, and earns the company $30 million in profits annually. This program also earned the highly coveted Henry Ford Technology award.• Led a go fast program (9 month development cycle compared to typical 48 month cycle) to integrate a complete vehicle acoustics strategy to attain planned attribute targets. Launched on time, on budget with zero launch issues. Show less

Dearborn, Mi

Senior Development Engineer, New Product Development, 1996 - 2000 Responsible for systems engineering for fuel cell research and development, within powertrain and propulsion systems.Major accomplishments:• Developed Energy Storage model for Fuel Cell Electric Vehicles (and published Thesis).• Developed a stand alone electric power generation system based on Fuel Cell technology.• Assessed international technology in Tokyo, San Paolo, Frankfurt, and Detroit.

Responsible for supplier development with emphasis on Auditing QS9000, Q1, APQP, PPAP, QOS deployment, Lean Manufacturing, and problem solving.Major accomplishments:• Annual Audits of 30+ Suppliers, QOS; managed supplier rating and remediation.• Drove supplier selection and development in North America, Europe, Asia, and South America.• Achieved critical targets in purchased components cost reduction by implementing synchronous manufacturing cells with Key/Strategic suppliers.… Show more Responsible for supplier development with emphasis on Auditing QS9000, Q1, APQP, PPAP, QOS deployment, Lean Manufacturing, and problem solving.Major accomplishments:• Annual Audits of 30+ Suppliers, QOS; managed supplier rating and remediation.• Drove supplier selection and development in North America, Europe, Asia, and South America.• Achieved critical targets in purchased components cost reduction by implementing synchronous manufacturing cells with Key/Strategic suppliers. Typical improvements included: Reduce setup times by 70%, reduce direct labor by 12%.Developed an APQP program and rolled it out to a 300+ International supply base for Ford Motor Company’s Electrical and Fuel Handling Division. Show less

Greater Detroit Area

Manufacturing Engineer, Cadillac Manufacturing and Quality EngineeringResponsible for final assembly at Hamtramck Assembly Plant; and statistical tools at Grand Blanc Stamping.Major accomplishments:• Process and Tooling Development for Interior and exterior Trim Installation and Testing• In plant launch support resolving critical work stop issues.• On going (7 days/week) production problem resolution.• Applied statistical tools to resolve issues.

Master'S Degree, Manufacturing Management

Bachelor'S Degree, Mechanical Engineering

Master Of Science (Ms) Mechanical Engineering, Mechanical Engineering