ORC Expert Advisory Services ORC International

  home    |    find an expert    |    request an expert    |    join our network    |    about us     expert login  
Expert Consulting and Expert Witness Services
  
  search tips 
Share this page:  Send to LinkedIn Send to Facebook Tweet This Email Print

 Expert  726353

Expert in Lean Manufacturing, Kanban


Available for your Consulting and Expert Witness Needs

Michigan (MI)
USA
Education Work HistoryPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Led implementation of lean (Toyota Production System) across the company. Directed a team of lean consultants, change management experts and plant lean leaders. • Drove implementation by initiating and guiding plant projects focused on creating continuous flow and kanban pull systems based on value stream maps. Trained and coached leaders and project teams on lean tools and management practices. Typical projects saved over 20% in labor cost and reduced manufacturing lead times 80%. • Established an effective and self-sustaining lean production system by introducing a full gamut of lean practices. Established lean management system including standard work for leaders, daily accountability meetings, hourly team leader roles and shop floor level root cause problem solving. Introduced heijunka and job instruction training, trained shop floor leaders to train their own employees on lean, and initiated weekly kaizen events in plants. • Built organizational alignment to eliminate barriers to progress. Simplified hourly classifications and pay, established high expectations and discipline for employee performance, and implemented flexible plant utility connections to facilitate quick relayouts. • Saved over $40 million in manufacturing costs, reduced inventory over 30% and reduced floor space over 50%, enabling plant consolidations worth $30 million more in savings. • Launched lean in non-manufacturing business processes to gain further efficiencies

 • 

lean manufacturing

 • 

continuous flow manufacturing

 • 

focused factory

 • 

just-in-time inventory

 • 

kanban


Show Secondary and Basic Areas of Expertise
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Grand Rapids, Michigan;  Flint, Michigan;  Lansing, Michigan;  Ann Arbor, Michigan;  Kalamazoo, Michigan;  Wyoming, Michigan;  Saginaw, Michigan;  Battle Creek, Michigan;  South Bend, Indiana;  and Elkhart, Indiana.

Often requested
with this expert:

Materials and Manufacturing Management
Green Energy Controls, Automotive Manufacturing,...
Lean Manufacturing, Lean Project Management, Lean...
Lean Manufacturing Engineering and Production Systems...

Education:
Year   Degree   Subject   Institution   Honors
1991   MBA   Strategy, Finance   University of Michigan - Ann Arbor   High Distinction
1985   BSE   Industrial & Operations Engineering   University of Michigan - Ann Arbor   Magna Cum Laude, Tau Beta Pi, Alpha Pi Mu

Work History:
Years   Employer   Department   Title   Responsibilities

2007 to 2009

 

Steelcase, Inc.

 

Corporate Strategy & Development

 

Director, Corporate Strategy Projects

 

Executed projects for the Vice President of Corporate Strategy at the request of business unit presidents or the CEO. Developed framework to evaluate consolidation of common functions including marketing and design across independent business units resulting in increased efficiencies.

2005 to 2007

 

Steelcase, Inc.

 

Operations

 

Director of Operations Strategy - Product Complexity Reduction

 

Led cross-functional project teams in this Board of Directors strategic initiative to simplify product offerings and raise profit margins. Replaced a redundant, low margin collection of products with a platform-based coherent portfolio of products with distinct features and price points. Reduced part count 72% and raised margins by $35 million.

1999 to 2004

 

Steelcase, Inc.

 

Manufacturing

 

Director of Lean Implementation

 

Led implementation of lean (Toyota Production System) across the company. Directed a team of lean consultants, change management experts and plant lean leaders. Saved over $40 million in manufacturing costs, reduced inventory over 30% and reduced floor space over 50%, enabling plant consolidations worth $30 million more in savings.

1995 to 1998

 

Steelcase, Inc.

 

Operations

 

Manager of Operations Planning

 

Directed an operations strategy staff group in developing manufacturing strategies to reduce fixed costs. Led development of North American manufacturing strategy, to free up two million square feet of space for new products and save $15 million per year in overhead and logistic

1991 to 1994

 

KPMG Peat Marwick

 

Consulting

 

Senior Consultant

 

Implemented Activity Based Costing (ABC) in diverse service and manufacturing businesses

1990 to 1990

 

MINISTRY OF FINANCE OF POLAND

 


 

Financial Analyst and Consultant

 

Analyzed competitive position of state-owned enterprises in order to select candidates for privatization.

1987 to 1989

 

Procter & Gamble

 

Manufacturing

 

Quality Manager

 

Reduced defects 90% in papermaking operation by building customer and quality focus.


Publications:
Publications and Patents Summary

He received patent number 6797219 for co-inventing a method of manufacturing floor tiles.


Consulting Services:
Selected Consulting Examples:
  • He directed a team of lean consultants, change management experts and plant lean leaders. He trained and coached leaders and project teams on lean tools and management practices.
  • As a senior consultant he led project teams.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

International Experience:
Years   Country / Region   Summary
1990 to 1990   Poland   As financial analyst and consultant, he worked with the Ministry of Finance of Poland to analyze the competitive position of state-owned enterprises in order to select candidates for privatization.

Market Research:
He has applied lean methods in the furniture industry to processes like stamping, welding, assembly, and wood fabrication. He has dealt with highly variable demand, make to order production and small lot/high mix production. In the Office Furniture industry, he has optimized the product mix to offer the variety demanded by customers without adding unneeded complexity.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:
Training/Seminars

He has developed and delivered training on lean manufacturing, value stream mapping, kanban pull systems, continuous flow production, heijunka, standardized work, and lean management systems including daily accountability meetings, visual controls and standardized work for leaders. He has developed and delivered training on product complexity reduction.

Supplier and Vendor Location and Selection

He has met and worked with a variety of Toyota trained lean experts.


 

Need the right expert?  We can help!

home       find an expert       request an expert       join our network       about us

Intota is now ORC Expert Advisory Services

FOLLOW ORC ON