Wayne Flatt Email and Phone Number

•Led cross-functional teams in the development, design, and implementation of continuous improvement Six Sigma projects following D.M.A.I.C techniques.•Improved existing equipment performance and production processes at four locations through Value Stream Mapping and Cost Benefits by an average of 19 percent.•Championed tooling changes that increased production throughout by 18 percent while reducing scrap by 30 percent.•Championed electric utility operations and cost improvement programs which reduced monthly energy costs by an average of 15 percent per facility.•Implemented and managed Process Control Plans and CTX’s practices for continuous improvement.•Co-wrote, developed and trained staff in the implementation of safety lock-out/tag-out program.

•Full responsibility for strategic planning, development, operations, and P&L.•Identified and eliminating high-risk activities and reduced employee injuries by 50 percent.•Responsible for equipment availability, performance, and uptime at four manufacturing facilities. •Implemented new corrective and predictive maintenance programs that alone increased equipment availability and uptime by over 22 percent.•Improved delivery performance from 78 to 99 percent.•Championed tooling changes that increased production throughout by 18 percent while reducing scrap by 30 percent.•Reduced WIP by combining secondary operations which increased part profits and opened floor space for additional work. •Managed all capital projects for equipment, facilities, and new construction. •Selected suppliers and negotiated all MRO crib items averaging 2.4 million annually.•Implemented and managed Process Control Plans and CTX’s practices for continuous improvement.

•Developed and launched national operations, installation & service organization to support new line of power-generation products. •Qualified, selected, and managed 32 distributor centers in North America. •Managed controls and performance engineering staff in development of product functionality, interface, and system configuration.•Implemented product support infrastructure of training programs, installation, service and repair manuals.•Responsible for site installations, local permits, and transport.•Responsible for managing site construction of new power stations and industrial buildings.•Interfaced with R&D department on field product reliability and performance.•Implemented and maintained cost-effective inventory of parts, meeting manufacturing and consumer demands while minimizing overhead expenses.•Defined and executed competitive pricing strategies around equipment, labor and competitors to optimize profitability and sales performance.

•Managed cross-functional team of more than 40 personnel through concept and program execution, ensuring required timing and deliverables were met.•Developed process and build specification for robotic tooling\fixtures of automated systems.•Developed station concepts, pricing, and deliverables.•Directed simulation studies of manufacturing lines and plant layouts to insure highest production rate.•Analyzed system cycle times and projected throughput rates.•Managed costs and suppliers for design, build, and delivery of system equipment.•Developed preventative maintenance requirements and schedules.•Assisted customer in ergonomics, staging of material and staffing placement.•Supported sales in proposals of potential new projects.•Performed supplier quality surveys and assisted suppliers in resolution of any concerns or deficiencies.•Project accomplishments include TRW SHI, TRW ADI9, Die Makers, Medway Plastics and others.

•Prepared and maintained project schedules, tasks lists, budgets and accurate forecasts. •Managed internal and external employees during integration and installations of robotic systems through startup at customer site.•Established run off documentation for customer acceptance.•Interfaced with customers to determine proper applications for their product and to resolve concerns and determine permanent corrective actions.•Performed final review of proposal submissions for manufacturing systems.•Assured projects were executed to ISO 9000 standards.•Consistently exceeded company expected margins.•Created department procedures to reduce costs and increase efficiencies. •Received CASA/SME Industry Lead Award for RA 90 Computer Assembly •Project accomplishments include American Axle, Masco-Tech Hydro Form, Guardian Glass, GMPT Flint, GMPT Warren and others.