Stephen Constable Email & Phone Number

Downingtown, Pa, Us

Downingtown, Pa, Us

Morgantown, Pa, Us

The foremost truck body manufacturer in the U.S. with 11 plants across the U.S. and Canada. Maintain leadership for all 11 manufacturing plants across North America, representing $450 million in revenue. Developed the corporate lean strategy and quality system. Managed corporate engineering, product development and manufacturing with responsibility for Responsible for 20 direct, 150 indirect and 1,700 hourly employees.■ 70% reduction in cycle time, a 56% decrease in warranty cost and a 25% boost in productivity achieved by introducing and standardizing lean strategy across all eleven manufacturing plants, implementing one-piece flow and eliminating work-in-process materials.■ 56% drop in warranty expenses generated in one year by conceiving a quality model that included a zero defect culture, quality at the source, data driven, problem solving and standardized work instructions.Optimized facilities with job-by-job content variation by exploiting a unique lean system that evolved into the lean strategy company-wide and from which all continuous improvement strategies materialized.■ Improved engineering productivity and quality while obliterating product recalls by creating a strong product development process.■ 56% decrease in warranty complaints attained and new contracts awarded by championing transformation to a culture striving to exceed customer expectations.■ 25% increase in productivity in 2.5 years accomplished by installing a computer tool that analyzed and forecasted plant backlog to provide visibility on content and labor variability, which enabled planning for optimal production.

Morgantown, Pa, Us

Developed a state-of-the-art program management organization for this multibillion-dollar automotive parts supplier. Implemented first class program management processes and established global infrastructure. Managed 25 direct reports.■ 35% spike in flawless launches won by developing and deploying program management globally.

Implemented a strategy for a new product line with accountability for product line growth and profitability via flawless launch and brand management. Oversaw new product development, pricing, sales promotion. Elevated brand awareness and market acceptance by leveraging the expertise of a cross functional team.■ Conceived a detailed business plan that incorporated a successful product, engineering, manufacturing, quality, finance and marketing.

Implemented lean manufacturing techniques in a 2,000-employee plant with $1 billion in revenue to serve as a model to 189 other plants.■ 99.6% first pass yield generated, a 70% improvement, by eliminating rework and focusing on quality at the source and final assembly.■ 90% reduction in lost-work days and a 71% decline in recordable injuries garnered by establishing ergonomic improvements and optimizing production.■ 65.7% increase in annual revenue per employee captured by enhancing productivity through cellular manufacturing and acquiring new business.Awarded the Shingo Prize in manufacturing excellence by introducing lean transformations.■ 65%+ rise in productivity obtained by reducing labor, elimination of waste and rework.■ 54% surge in revenue earned per square foot and a 30% drop in the energy cost per steering column produced by upgrading manufacturing facility layout and using a cellular machinery arrangement.■ 37% spike in on time delivery realized by establishing process improvements and lean strategies such as quick changeover, cell manufacturing, Kanban and enhanced uptime.■ Selected as one of Industry Week magazine's top ten best plants in North America due to the lean transformation initiatives.■ 1st plant in North America to achieve both the Shingo Prize and Industry Week's top ten best plant list.

Conceptualized the worldwide manufacturing strategy and footprint for 190+ plants that led to the Delphi Manufacturing System (DMS). Instituted key metrics to appraise plant performance and created a process to track monthly performance to give leadership vision into under-performing operations.********************* ADDITIONAL CAREER EXPERIENCE *********************➤ General Motors, Inc.Engineering Manager, Global Brake SystemMilford, MI$152 billion multinational corporation designing, manufacturing, and distributing vehicles and parts. Developed the brake systems engineering organization to conceive, validate and commercialize production that changed the company from a parts supplier to a brake system vendor and grew business.➤General MotorsSuperintendent of ManufacturingLivonia, MI■ 16%+ sustained improvement in first time quality (FTQ) fostered in six months by using Shainin Red X problem solving, straight through flow and abolishing work-in-process.■ Zero premium shipments achieved to reach an historic benchmark by leveraging problem solving skills.

Bachelor’S Degree, Mechanical Engineering

Lean Manufacturing