Vertically integrated electroplating.Beginning implementation of lean manufacturing assembly work cells.

Delivered 150% increase in production capacity. Improved on-time shipping performance by 80%.Reduced projected component stock-outs by 75%.Developed demand-based predictive staffing model.Implemented robust IT backup and disaster recovery solutions.

Developed and began implementation of factory transformation strategy to double manufacturing capacity by leveraging lean manufacturing techniques.

• Managed team of 25 engineers and technicians across multiple locations in the US and Mexico.• Collaborated with Lowe’s quality team to save 50% on packaging costs while still reducing product damage and customer returns by 20% by utilizing customer surveys, data analysis, testing, and detailed investigation of the entire distribution process.• Invented industry-changing, patent-pending cabinet hardware components such as low-cost ball bearing drawer glides, reducing production costs by 50% in materials and labor and resulting in incremental sales to Lowe’s and The Home Depot. • Managed $1.5M department budget; set new standards for product development quantity and quality.• Created dynamic cost model for a fully customizable product line with millions of potential configurations to render profitability analysis.• Approved final costs for new products including labor, overhead, manufacturing, and imported materials. Created new models and methods to determine labor, material, and freight costs.• Advised C-level regarding new product development costs, manufacturability, and bottom line results.• Turned around product development cycle speed and quality to meet RSI marketing demands for high volume; collaborated with sales and marketing teams to bring innovative, cost effective solutions to market.• Implemented automation and standardization to improve product development process.• Launched RSI’s made-to-order kitchen product line, including establishing new manufacturing processes.• Collaborated with sourcing division in China to develop new cabinet components and hardware.• Created and standardized test protocols for products and components in both development and production. Developed standardized testing procedures in use as customer’s official test process for the entire product category.• Developed and implemented alternative technical career path to provide opportunities for engineering career advancement without moving into management roles.

• Turned around under-performing made-to-order cabinet assembly plant in North Carolina as interim Plant Manager, directing a cross-functional team of 150.• Improved operating efficiency from 60% to 90%.• Reduced back orders from three months to two weeks; eliminated finished goods inventory, shipping backlogs to customers to retain loyalty. • Designed and implemented new material allocation software and processes.• Implemented lean manufacturing processes, including single piece flow throughout the factory.

• Saved $1.4M annually in logistics expense by relocating medicine cabinet assembly from California to North Carolina.• Managed 300,000 square foot facility expansion.• Installed and commissioned over $2M in capital equipment for capacity expansion.• Reduced setup times on panel processing line from 45 minutes to 7 minutes utilizing SMED principles.• Improved overall mill efficiency by 10% by implementing visual management tools.

• Drove innovative manufacturing processes for North Carolina manufacturing facility to support sales of $49B in 2005, and to maintain Dell’s #1 market position throughout tenure. • Negotiated $10M of material handling automation equipment after specifying and sourcing.

• Managed 30 to 60 employees for three desktop computer boxing lines, with a 50% permanent/temporary ratio.• Increased production by approximately 30 boxes a day and set hourly run rate record on Dell’s semi-automated boxing line, packaging 300 to 350 computers per hour.• Utilized robotic lines to run over 700 boxes an hour, troubleshooting downtimes in technology.• Achieved zero OSHA-recordable injuries and best boxing quality results across all Dell factories worldwide.

• Contributed to Dell’s return to #1 market position in 2003 after losses and layoffs in 2002.• Improved productivity by 25% and reduced square footage requirement for kitting by 40% through development and implementation of new kitting process for Dell’s existing server assembly line. • Designed and implemented new server assembly lines which increased manufacturing productivity by 50%, reduced new assembly line capital expenditure by 50%, and reduced square footage requirements by 20%.• Drove project in Dell’s largest desktop PC factory to improve uptime due to materials availability, reducing materials-related downtime from 15% to 2% and reducing cost per box by $1.55.

• Contributed to Dell’s ascent to the #1 PC producer globally in 2001.• Developed, implemented and patented the factory integrated shipping process in Dell’s North American Distribution Center including installation of a $20M automated material handling system.• Reduced floor space requirements for international shipping from 50,000 to 5,000 square feet.• Reduced headcount requirements by nearly 50% by eliminating an off-site shipping facility.• Secured funding for $9M upgrade to increase distribution capacity.• Saved $360,000 per year by developing solution to automate shipping label application.• Designed and implemented a just-in-time material process to eliminate a 60,000 square foot warehouse, reducing on-hand inventory by $2.27M, and saving $111,000 per month.• Created and implemented an automated process that reduced commodity count time in the distribution center by 60%.

Reduced machine setup times 50% by developing a new process that identified optimal machine settings in a co-fire circuit board screen printing process.

Evaluated custom product designs for manufacturability; designed and implemented safety enclosures and fixturing for machinery.

Conducted pre-production pilot runs of new product assembly lines;utilized thermoplastic and thermoset injection molding.