Liquids/Hand Care Value Stream Manager
Us
Managed 2 value streams accounting for $100M+ revenue. Led a team of 3 supervisors, 5 maintenance personnel, 2 production planners and 80 union personnel. Drove key Operational Attributes of EH&S, Quality, Delivery, and Cost. Value Stream Mapping utilized to identify kaizen opportunities to develop a transformation plan for value streams and corresponding rolling 6 month implementation plan that aligned with the company’s overall strategy.• Developed and implemented standard work in compounding process resulting in a 15% quality improvement in first pass yield and a 30% labor reduction to produce equivalent gallons/man hour • Led two kaizen events with Shingijutsu Global Consulting, (Toyota lean manufacturing partner) leading to 52% productivity improvement, and lead time compression, resulting in $143k inventory reduction • Reduced production cell space by 41% utilizing kaizen events• Developed, redesigned and implemented the conversion of 7 traditional production lines into cellular manufacturing units leading to a 37% productivity improvement in gal/ MH and a 53% reduction in labor cost per gallon• Consolidated two shift operations into a single shift leading to the reduction of 24 union employees, 1 maintenance personnel, 1 production planner and 1 production supervisor – resulting in an annual savings of $750k• Reduced Inventory by 47.5% ($629k) in 5 months while improving order fill rate for industrial sales by 8% and maintaining a 99.8% order fill rate for retail sales channel• Reduced water usage by 43% in washout process