Rob Morell Email & Phone Number

Barneveld, Wisconsin

Middleton, WI

Middleton, WI

Madison, Wisconsin Area

Madison, Wisconsin Area

Richmond, IL

• Led three production teams consisting of 50 people across 3 shifts, responsible for about $7M in outside sales and supporting about 85% of site business.
• Led one A2LA accredited lab team responsible for serving multiple industries
• Led one production support team consisting of operator technicians and machinist
• Reduced past due backlog from $110k to $15k in two months, eliminated backlog in six months
• Improved On-Time manufacturing performance from 30% to 90% in six months
• Improved first pass yield (FPY) from 80% to 95%

Richmond, IL

• Facilitated the learning and use of lean tools, with special focus on Process Preparation (2P), the Production Preparation Process (3P), Setup Reduction, Error Proofing and Total Productive Maintenance (TPM).
• Facilitated 3P Rapid Improvement Event (RIE) that reduced Standard Work in Process (SWIP) from 125 to 5 pieces.
• Facilitated setup reduction RIE that reduced setup time from 8 minutes to 3 minutes (62%) and increased productivity from 19 units/hr to 23 units/hr (21%)
• Facilitated 2P RIE that enabled a paradigm shift of batch processing to one-item-flow in a legacy production area.
• Became Lean Silver Certified
• Championed development of a site creative space called "The Moonshine Room"

Columbia, Missouri

• Led two mixed-model, high variation work centers, consisting of 21 team members across 2 production shifts, ensuring human development, quality, delivery and productivity goals are met
• Improved people survey results 13%
• Reduced customer lead time from 20 to 10 days
• Increased productivity 23%

Columbia, Missouri

• Facilitated the learning and use of lean tools in both manufacturing and administrative areas to implement managing for daily improvement (MDI)
• Led rapid improvement event (RIE) to transform a traditional manufacturing cell into a lean, mixed-model manufacturing cell
• Facilitated RIE that reduced customer lead time from 15 to 10 days and shifted the paradigm around production scheduling
• Became Lean Bronze certified

Richmond, IL

• Led a team which reduced process time for creating product certifications from 480 seconds to 40 seconds and quality issues by 85%
• Assisted in the identification and elimination of legacy products that required large sustainment costs without yielding sufficient profit margins
• Pioneered Customer Acquisition and Retention Team (CART) problem solving team, the first for an administrative team within the facility, to reduce non value-add activity
• Provided thermal sensor support for challenging customer applications

Richmond, IL

• Coordinated the design, fabrication, testing and delivery of production equipment, implementing it on time and to cost, while reducing quality issues associated with the manufacturing process by 90%
• Used design of experiments (DOE) to understand key variables associated with production equipment in order to optimize process cycle time while meeting customer specifications
• Provided engineering support to production staff to maintain progress to safety, quality, delivery and cost goals

Madison, WI

• Designed, fabricated and calibrated test setup to measure thermal conductivity of unknown fluids for ongoing laboratory use
• Designed and constructed capacitive sensors in a constant flow loop to measure void fraction
• Authored technical documents outlining experimental design, testing and results

Wauwatosa, WI

Instrumented and tested structural components (frames, swing arms, wheels, forks, etc) and powertrain components (sprockets, transmissions, compensators, pivot shafts, etc) to failure under various conditions.Developed benchmark process to replicate "on road" testing, increasing test efficiency and reducing test cost.