Sid Gray Email & Phone Number

Boise, Idaho Area

Guiding small and medium size businesses in developing a Lean and Continuous Improvement culture.Well versed in Sewn product, injection molding, assembly, ISO and standardized quality systems,

Boise, Idaho Area

• Facilitate growth in LEAN processing at facilities producing outdoor products. Implementation and daily use of Lean systems:
• Safety awareness training, audits & Gemba. 50% TRR reduction during last 3 years.
• Visual management systems at every level (cell to multiple sites)
• Kaizen events resulting in an average of 50% reduction in touch labor
• Pull systems – visual raw, WIP and finished goods. Water spider sustained systems.
• Established Escalation processes, Tiered meetings, Strategic Deployment roll down & review process

Boise, Idaho Area

• Acquired by ATK
• Built QMS at Meridian site from scratch designed for ISO registration.
• Led Blackhawk! Manufacturing sites to ISO 9001 Registration in 2008 as the QMS administrator
• Installed Lean processing in Production areas with a DL cost reduction of 45%
• Facilitated documented savings of $300k yearly utilizing employee suggestion systems
• Lead teams growth in a Lean journey from large batch systems towards 1x1 flow (PDCA experiments)

Ohio

• Managed daily activities of 180 employees from raw receiving, manufacturing, to shipping finished product
• Reduced direct labor costs by 40% through standardization and establishing clear expectations
• Created costing system that reduced time to process new product by half.
• Reduced final inspection process through standards and returning ownership to production
• Introduced visual management, point of use Kanban, hourly Takt times, and standard work.
• Eliminated weekly overtime requirements while still maintaining delivery schedule

Boise, Idaho Area

• Directed daily activities of support a support team that included individuals supporting Quality Assurance, Industrial and Manufacturing Engineering, training, and new product costing, Bill of Materials & processing.
• Reduced direct labor requirements by half resulting in a $1.6M savings during full period of operations
• Improved productivity of the plant by 70% while reducing DL headcount by more than half.
• Developed customer return process that captured relevant data for operations reaction protocol

Greater Salt Lake City Area

• Reduced processing time requirements by 50% by utilizing visual management systems & flexibility in team processing
• Established start of shift pass down and escalation meetings to ensure department continuity over 24/7 operations.
• Improved department response time and accuracy during tenure by 50%. Eliminated production line down time due to parts waiting for inspection beyond plan.
• Reduced raw and WIP returns processing time by more than 25% & pulled process to within 8 hour determination goal.
• Created visual system for Quality Engineering review process that reduced time to process by 40%

Colorado

• Provided transitional leadership following a contentious employee strike center on Employee Engagement and providing leadership centered on providing the employee with what they need to complete the job.
• Developed a QMS that resulted in ISO registration in 1998
• Improved turn out gear design and construction methods to meet revised NFPA standards that resulted in UL certification
• Created a training system with written documentation of standard work and quality specifications
• Created a visual system on production floor to clearly identify priorities and guide team activities
• Reduced employee turnover by creating pre-hire skill testing and experienced operator mentoring process.