Manufacturing, Operations & Engineering

Situation:
Morale, organizational, quality, technology, and equipment problems had company losing business, saw margins declining and major customers telling owners the companies products were being made obsolete by new technologies.

Accomplishments:
• Implemented flat line organization to develop consistent message and evaluate staff
• Built appropriately balanced team, replacing managers, and put key players in the right slots
• Identified problem areas in all functional areas
• Developed and implemented strategies and action plans to fix major problem areas
• Lead move to use of statistical tools to improve quality
• Used statistical process control tools, and formed attack teams to decrease scrap 50%
• Used statistical tools and teams to increase uptime/ productivity on machine centers 50%
• Developed new overhead reporting by process and product
• Led move new computerized material control system
• Used statistical processes to reduce tool expenses
• Planned, organized and implemented combining two plants reducing break even 25%
• Built team and provided leadership to move combined plant staff from 80% aftermarket to 95% O.E
• Led team to dramatic quality improvements leading major supplier quality awards

Results:
• Engineered product line 10 fold;
• Combined divisions have grown 500%
• Achieved 5-year 24% sales growth and 19% growth in profits
• No customer was more than 15% of revenue
• Made Fortune list of top 100 growth companies
• Recognized as a quick to market, high quality supplier of “black box” engineered products.