David E. J. Email & Phone Number

Berkeley, Ca, Us

Bluegrass Living is an American OEM manufacturer of heating, hearth, and outdoor living products. We started in 2002 producing space and construction heaters and quickly expanded production to meet the growing market demand.In 2006 we invented and patented the first dual fuel technology for our products. Since 2012 we have focused on bringing production of our products back home to the United States with a new production facility for both our heaters and fireplaces. Bluegrass Living has taken advantage of new technology to help bolster American jobs and our economy. We have always driven to be innovators in our field and have no plans of stopping that trend.With over 100 patents on products across the globe, we are only just beginning. We believe that innovation is a necessary core value to sustain a competitive advantage and to offer the best quality product for the money.

Performed site visits and diagnostics of our client’s operation.For an automotive Tier I supplier of body components designed a lean assembly line with flexible manpower to reuse capital investments.BOM review for electric vehicle startup to ensure all components were accurate and optimized for cost-effective prototype assembly which directly increased production readiness. Supported the launch of high-volume BEV battery module production lines at GM SpringHill (08/2023 - 12/2023).Designed and fabricated advanced automated material handling AGV (Automated Guided Vehicle) for a Tier I Japanese automotive company utilizing 3D modeling and printing techniques coupled with Arduino-based programming, reducing total delivery costs by 75% through the development of efficient Alpha & Gamma prototypes.Revitalized operational processes at a Steel Tubing Manufacturer and re-implemented lost management processes to boost OEE to 93%. Eliminated non-essential shifts and fostered a supportive work environment through strategic HR initiatives, increasing employee satisfaction and productivity.Transformed quality management for a leading hot tub manufacturer in Tijuana, MX, by instituting self-inspection protocols and root cause analyses; initiated Capex plans that realized 150% cost savings ($11.6M) while addressing leakage issues.Supported team with streamlining container operations at Rail intermodal terminal by conducting extensive time studies to understand and recommend optimization of loading and unloading processes to enhance logistics efficiency.

Justin, Texas, Us

Directed a highly skilled team across California and Michigan including two managers, 30 engineers, 50 assembly, and 10 repair technicians to drive advancements in EV assembly and battery module production. Administered $50M CAPEX and operating budget while ensuring cost-effective management of gamma, as well as first factory builds and delivering all projects on time and under budget. Oversaw design and procurement of critical equipment for one of North America’s newest vehicle and battery assembly plants, focusing on enhancing the facility’s capacity for high-volume production.Scaled up prototype operations tenfold in the general assembly and high-voltage battery modules & packs, resulting in the production of over 1,000 high-quality battery modules and 20 unique fully electric 350 eHp rolling skateboard assemblies.Navigated critical supply challenges by managing approximately 12 equipment suppliers to facilitate uninterrupted supply of process equipment even under tight deadlines.Fostered team development and integration by mentoring a young team of engineers who were new to vehicle production and effectively bridging knowledge gap between them and seasoned manufacturing professionals.Managed daily operations through Gemba walks with operations managers and group leaders to swiftly address production issues and increase efficiency.

Franklin, Tennessee (Tn), Us

Revamped manufacturing and quality systems for a German luxury vehicle manufacturer by developing and implementing a strategy that aligned with stringent quality standards. Provided ongoing support and training to production managers and group leaders to enhance floor management and safety protocols.Realized cost savings of $11.5M for a Yearbook/Jewelry Company by redesigning manufacturing operations and instituting lean practices, significantly surpassing the $1.5M targetImproved OEE from 4% to a peak of 93.9% within 15 months by introducing a downtime monitor system and implementing line-stopping protocols for immediate equipment repairs.Consulted on major cost reduction initiatives at USA's number one pickup truck OEM while collaborating closely with Chief Engineers and traveling to various sites to implement strategic cost-saving measures across different vehicle models.Reduced operational costs and inefficiencies by introducing an Andon board system, subsequently standardized across multiple shops to track and enhance productivity.

Directed the launch and rapid scale-up of a new automotive plant which transformed failing company operations; achieved an average OEE of 93% and quality rate of 99.98% through implementation of Vorne® productivity devices and advanced management practices.Grew the business from $0 to $8M, elevated production capabilities, and introduced high-speed manufacturing processes that reduced cycle times from 2.5 seconds to 1.7 seconds.Instituted a continuous improvement culture by incorporating daily kaizen activities that markedly improved team morale and operational efficiency while reducing change-over times from 120 minutes to 20 minutes.Cultivated strong partnerships with educational institutions such as the Tennessee College of Applied Technology to integrate skilled trades from cooperative education programs into the workforce; improved manufacturing capabilities, enabling the plant to outperform HQ in productivity by a ratio of 3:1.Developed and executed Hoshin Kanri business plan, focusing on KPIs to drive operational excellence and strategic alignment across the organization.Assembled and led a high-performing team by effectively recruiting, incentivizing, and motivating staff to deliver dynamic business results while overcoming initial gaps in market knowledge.

Yokohama-Shi, Kanagawa, Jp

Spearheaded supply chain operations for six vehicle models including managing over 30,000 parts in a 6,000,000-square-foot facility, focusing on enhancing process productivity and operational efficiency. Cultivated strategic partnerships with suppliers across NAFTA which drove $50M annual reduction in total delivered costs and integrated team efforts with supplier departments to co-develop and implement cost-saving measures.Engineered RFID Andon kitting lock system that reduced mis-picked parts by 95% and minimized $5M annual profit loss due to line downtime. Led transformative initiatives in the supply chain, reducing injection mold press change-over times from 75 minutes to 15 minutes, as well as driving 25% cost reduction without additional capital expenditure.

Aurora, Ontario, Ca

Directed manufacturing cost control for the highly profitable hard and soft-top retractable roof business; entrusted to manage direct reports across quality, production, customer service, repair, supply chain, and engineering endurance testing management teams. Drove strategic decision-making by conducting weekly reviews of operations and quality performance with the board of directors. Transformed the business failing in new product launches to the most profitable group in the global business unit of retractable roofs by driving quality improvement and cost optimization initiatives to eliminate costly shipments from South Korea, China, and Mexico.Grew First Time Quality from 2% to 98% within three weeks through the implementation of sequential mix-model production strategies; reduced manufacturing time by 65% and boosted profitability without outsourcing.Led product launch of the world’s first SUV convertible and pioneered new design standards and manufacturing processes, thus setting a new benchmark in the automotive industry.Reduced labor by 25% and assembly floor space by 75% by pioneering the world’s first kitting process of an Austrian OEM that enabled implementation of the first-ever sequential mix-model assembly line for soft-top retractable roofs with synchronized work carts. Halved both investment and lead time by performing manufacturing due diligence to relocate a plant over 200 km using 3D digital factory techniques.

Toyota City, Aichi Prefecture, Jp

Project leader for the launch of Lexus’ first-ever 3-piece hard-top convertible utilizing cutting-edge 3D digital tools to reduce tooling development time by 50%, achieved production readiness 18 months ahead of schedule, and set a new benchmark for speed and efficiency at Toyota.Awarded 1st Place in the all Toyota Japan Kaizen competition for innovations on the Lexus RX350 rear suspension assembly line; led the teams to reduce CAPEX by 30% and labor costs by 25% through lean manufacturing principles.Led digital factory planning analysis as the first non-Japanese final assembly production engineering team leader for new models in North America; reduced equipment planning and vehicle development time by four months (10%) and cut CAPEX spending by 30%.Selected for Toyota’s prestigious Foreign National Employee Program and trained extensively in Vehicle Investigation, Process Planning, and Equipment Planning; recognized for outstanding passion and dedication to operational excellence.