Terry D. Email & Phone Number

Warren, Michigan, United States

• Hired by Radiac Abrasives to perform a turn around effort at Acme Abrasive.
• The Executive Board approved $3 million to assist in the efforts.
• Enforced and created standard operating procedures (SOP) for production - increasing production output by 50%.
• SOPs decreased employee complaints, defects, & quality issues by 50%.
• Purchased two used forklifts to increase efficiency plant-wide.
• Hired additional maintenance staff, which decreased downtime & maintenance issues by 50%.

Detroit Metropolitan Area

• Oversaw a three-shift operation of four plating lines with 60 employees and had five managers (Maintenance, Chemistry, Wastewater Treatment, Logistics, and Quality) as direct reports.
• Instituted daily stand up meetings with all departments to increase internal communications and issue resolution, which resulted increased issue resolution and visibility by 100%.
• Instituted 5S and other lean manufacturing principles to increase production output by 50%, reduce down time by 25%, and reduce defects by 15%
• Co-led a 10-person cross-functional continuous improvement team across two plants to increase production training, quality, and efficiency each by 30%.
• Reduced safety incidents by 50% by enforcing PPE requirements, assisting with root cause analysis, and resolution.
• Created a visual production board for all four plating lines, which ensured production was on schedule and that issues were communicated in real-time.

• Reduced assembly changeover time from one hour to 25 minutes by developing visual changeover guides on the back of machine tool plates.
• Decreased molding changeovers from 45 minutes to 30 minutes by commonizing end of arm storage tool locations, storage, and labeling.
• Led lean sigma business kaizen sessions with project engineering, design engineering, sales, quality, and manufacturing, to increase tollgate approvals by 80%.
• Coached, counseled, and mentored manufacturing team leaders and operators to develop and hone problem-solving, troubleshooting, and continuous improvement tools to promote and empower lean culture.

• Developed quality documents to track J&J’s vaccine out of refrigeration time reducing quality defects by 50% and increased traceability by 100%.
• Assisted in the development and facilitation of on the job training to reduce manufacturing quality deviations across three shifts by 50%
• Created and/or revised master batch records, including, but not limited to all supporting documentation (i.e. specifications, change control, procedures, forms, labels, etc.) to reduce quality defects by 25%

• Supervised two 12 person bottling and blister packaging line operations for oral solid dose products.
• Developed a visual personnel crewing board for all three shifts that reduced staffing scheduling time from 30 minutes to 15 minutes.
• Utilized lean problem solving tools to lead and train method one investigations resulting in consistent training practices across all three shift and decreasing quality deviations by 30% across all three shifts.
• Restructured operator training to increase cross training and advance individual operator training by 75%.

Kalamazoo, Michigan, United States

• Managed a team of 50 contractors to pick, pack, and ship Pfizer’s COVID-19 vaccine with a 99.9% return rate.
• Assisted a team of 12 in demonstrating a semiautomatic packaging line and dry ice dispensing machine for the President of the United States.
• Led a team of 20 contractors to successfully pack out the initial 10 shipments of vaccine on national television.
• Corrected a reverse functioning set of four CO2 exhaust systems, which caused excessive CO2 monitoring alarms for personnel.
• Collaborated with EHS to streamline a 12 step CO2 monitor reset process that reduced the process time from 60 minutes to 30.
• Assisted EHS in developing a custom exhaust system for the dry ice tote dumpers that would allow operators to perform necessary tasks and effectively exhaust CO2.

Kalamazoo, Michigan, United States

• Utilized Microsoft’s Visio software to develop process maps for the receipt, unpacking, and storing of the initial 70 early use authorization vaccine shipments from Pfizer’s facility in Belgium.
• Created process maps for the picking and packing operations that became the standard processes for each operation.
• Assisted in the development, execution, and routing of SOP 33552, which governs the entire vaccine pick, pack, and ship operation.
• Co-led the commissioning efforts for two semi automatic packaging lines and two dry ice dispensing machines in order to successfully meet commissioning deadlines while the lead process engineer was quarantined.
• Worked with the manufacture of the dry ice tote dumpers to institute 15 functionality changes to the operating software that made the machine’s HMI and operating software user-friendly for operators.
• Developed datasheets 33552-F01 and 33552-F02, which would become quality documents used to pick vaccine from the ultra low temp. freezer and return vaccine to the ultra low temp. freezer.

Whirlpool Benton Harbor Technology Center

• Appointed as an onsite COVID-19 supervisor for 80 essential employees; instituted, adhered to, and enforced multiple policies and guidelines to ensure worksite health and safety.
• UL Mechanical Structures testing lead; certified to perform over 30 UL and IEC test procedures. -Trained techs in three Refrigeration Labs resulting in 25 UL and IEC certifications. -Led efforts to train new techs for.
• Drove reduction of testing time from >3 months to 3 weeks for Oberon Door Operations Fixture while reducing multiple downtime issues over lifetime simulation testing of 300,000 cycles, documented via A3.
• Led a Continuous Improvement project to automate Handle Cycling Testing which reduced test down time by 90 hours per year and saved 22 man hours on test per year, documented via A3.
• Communicated a critical observation of bubbling in the molding of the new refrigerator ‘Spring Fingers’ that was driving failure during Door Operation testing, resulting in selection of a new supplier prior to.
• Designed, fabricated, and assembled 20+ fixtures and testing processes for prototype testing ranging from automated actuated arms to simple pulley systems.

Whirlpool's Saint Joseph Technology Center

• Created SWI for new washing machine cycle verification testing; saved 40 hours of rework due to a defined test method.
• Trained techs in nuclear industry S.T.A.R. method in order to prevent the destruction of software flashing controllers and laundry units.
• Led monthly 5S and Safety Audits driving resolution of over 15 discovered issues, reporting resolutions to management with minimal downtime.

Various Fossil Fuel, Petroal Chemical, And Nuclear Plants

• Assisted in 3,000+ hours of valve, snubber, and nozzle dam repairs, replacements, and reinstalls at 15+ nuclear power stations delivering all projects on schedule and at cost.
• Experienced in training junior technicians in troubleshooting of systems, subsystems, and components through a vast array of technically complex nuclear safety systems on multiple job sites.
• Completed over 1000+ hours of continuing education comprised primarily of nuclear site based work safety training

Bs

Education record