Oversee the Cast House operations (schedule coordination with customers and vendors, raw material procurement, receiving, charging, melting, transfer, holding, degassing, filtration, casting, material movement, homogenization and cutting to length of log) which supplied three facilities with six unique sizes and fourteen unique alloys of extrusion billet/slab. Improved overall through put by 37%. Worked with supplier of the casting equipment, which supplied the equipment for the recently completed modernization, to resolve issues that existed since startup. Established a data collection system, a formalized metric system to measure progress and material requirements, implementation of Gemba board and daily, weekly and monthly reporting. Using the metrics, established current conditions and laid out and executed plans for improvement in the operations. Oversaw the expansion of the operation from a three shift 24/5 operation to a four shift 24/7 operation. The 24/7 operation change along together with all of the various process improvements resulted in record production in the most recent month by over 25%. Completed the technical and financial justification and ordering of a new cast diameter. Responsible for inventory control of raw material and hardeners for casting.

Assisting companies with material issues, flow and utilization.

Oversee the Primary, Industrial and Cathodic Departments. Lead scrap reduction efforts that resulted in record low scrap percentages - reduction of over 76%. Oversaw the modernization of the cast flow rate methodology. Evened out the production flow and material planning which resulted in customer shipping schedules with On-Time Delivery rates of over 99%. Oversaw the implementation of Gemba boards. Oversaw the activity for selection of the next generation melting equipment for replacement of existing technology. Help direct the efforts of the facility with implementation of several FranklinCovey courses (Leading at the Speed of Trust and 5 Choices) thru leading the implementation team and teaching the courses. Instrumental in development of several Zinc Secure alloys for coinage applications. Mentored direct reports, engineers and other personnel in the facility. Represented the company on various ASTM sub-committees.

Lead technical improvements in a priority extrusion process to increase yield by 226% and an increase in production by 471%. Developed methods to allow production of products for two new market areas. Increased product mix from two to ten items.Sole author on one patent and co-author on two other patents dealing with the extrusion side of the business

Oversaw growth and ramp-up of a startup operation situation including investor and customer interactions.

Program leader of a seamless tube wall variation reduction program where there was an increase of 118% in productivity and a 77% reduction in scrap. Designed and implemented a cost tracking system for the facility. Implemented a tooling management program. Redefined and implemented a baseline recipe control system. Managed the Cast House.

Key role in the evolution of Hydro Aluminum Production System (HAPS) from a tools based system to a full planning system that incorporates lean manufacturing techniques and principles into the future state plans of the facility. Developed capacity, scheduling and inventory management systems in a green field manufacturing facility.Ensured the Manufacturing Departments were fully supported during the training period of the new Engineers.Completed the activity associated with the Engineering Department as the Facility passed its initial TS-16949 Registration Audit.

Redefined work order system within the Laboratory.

Reduced customer complaints by over 60%. Reduced employee turnover by 40%. Achieved and maintained a safety TRI index of zero. Completed startup and production activities for major growth in two major business areas while meeting all production and delivery requirements.

Increase in productivity of 30%. Decrease in scrap by 40%. Reduced customer complaints by over 50%. Achieved and maintained a safety TRI index of zero. Implemented a new cutting technology (rotary and chip-less) thus allowing the elimination a major environmental concern and also allowed a reduction in manning.

Oversaw the activity required for the facility to become the first in all of Hydro Aluminum to become registered to QS-9000. Upgrading of the facilities, equipment and skill of the Quality Assurance Department to meet Customer and Market demands. Led design and implementation of a Cost of Quality system for the division. Oversaw implementation of a paperless Quality System.

Represented several companies while on the ASTM B07 Wrought Aluminum Standards Sub-Committee. Interacted with many other companies as both users and consumers.While a member of the Sub-Committee, served as President, Secretary and a member.

Real productivity improvements of over 12 % realized through effective production analysis and teamwork. Oversaw the successful on time installation of an emergency water system along with casting control upgrading. Completed equipment search and other activity on upgrading of the molten metal treatment capability of the Remelt. Continued to help oversee quality system implementation of ISO-9002 (Registration 9/95).

Successfully completed all documentation for registration to ISO 9002. Analyses of past successes to address culture change necessary for successful ISO 9002 registration.

Led the development of a 6XXX grain size controlled alloy for applications in automotive and impact forging applications. Oversaw activity to ensure 100% Customer and national specification compliance. Upgrading of the laboratory facilities to handle the increased workload to meet market conditions.Successful implementation of the Kaizen methodology for team orientated continuous improvement in various Alcan facilities (over 50 Kaizen activities – 2 day through 7 day events).

Developed a shear face extrusion technology for extruding metal matrix composites. Developed outside tolling sources. Achieved extrusion of high volume content composites. Involved in the initial production of the Title 3 entitlement program for developing the metal matrix industry.

Implementation and training of 2nd generation statistical process control. Installed a metallographic laboratory. Led successful efforts to eliminate environmental discharge violations. Led successful activity for development of new alloys. Led activity for development of a cleaning and coating operation in the nail painting operation. Developed the metallurgical processing relationships between grain size, heat treatment, amounts of cold work and degree of formability in the aerospace fastener industry. Led the development of Al-Li welding wire drawing manufacturing process for the Aerospace Space application. Key customer contact for quality and technical issues and development activities.

Initial development of grain refinement in continuously cast brass base tube through homogenization.

Located several applications in the petrochemical industry for two new state of the art boiling and condensing products. Served as a key contact for quotation and new product purposes.

Led study and analysis for complete elimination of eccentricity problems in seamless extrusion by completely redesigning the extrusion tooling. Installed a liquid nitrogen aluminum extrusion die cooling system including design of extrusion tooling for both ID and OD cooling. Installed statistical process control on a seamless extrusion press. Worked as the weekend line supervisor for the aluminum production areas.