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 Expert  729682

Expert in Market Trends, Lean Manufacturing, 5s, Six Sigma, One Box Set Up, Start Ups, Shut Downs, Design


Available for your Consulting and Expert Witness Needs

Arizona (AZ)
USA
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert is a globally recognized, award winning Multi-Plant Manufacturing and Distribution General Manager. He is the winner of the Global Six Sigma and Business Improvement “Best Achievement” Award for his success running multiple facilities in the United States and in Mexico for Temple-Inland. He orchestrated the best financial performance improvement of 2009 for Temple-Inland (third largest in the world). He is an expert in all facets of sales, manufacturing, branding, packaging and distribution. He has facilitated several plant start ups and turnarounds. He has managed multiple facilities throughout most of his career. He has presented at national conferences and been published in many publications. He led Value Added Sales Efforts for Stone Container, Smurfit-Stone, Marfred Industries and Temple-Inland. He is the founder and President of the fastest growing paper based packaging group/association in the world with over 4000 members since November of 2008. His team improved Average Sales Margins by over 20% in 2009 for Temple-Inland.

At Smurfit-Stone Container in Phoenix, he had Quality and ISO 9001 responsibilities over 11 Pacific Region plants and Safety responsibilities over 11 Southwestern Plants. He was on the Smurfit-Stone Merger Mobilization Team consolidating operations and producing nearly $100 million in annual savings. For his “Value Added” sales efforts as a packaging Salesman Expert was nominated for the corporate wide Project XV Value Added Sales Award for the largest box manufacturer in the world at the time. Expert was one of the few people out of a pool of 30,000 nominated for the Stone Container's Chairman's Award for my Quality, Sales and Supply Chain efforts.

Expert managed three facilities for Temple-Inland (Fortune 1000) in Edinburg, Texas, Nuevo Laredo, Mexico and Reynosa, Mexico before shutting down the Nuevo Laredo, Mexico facility and expanding value added manufacturing at the other two. They totaled 380,000+ square feet, 150 employees and over $60 million in sales. He was the Chairman of the Board of Directors for the South Texas Manufacturers Association and on the Board of Directors of the United Way of South Texas. Expert has also served on the boards of several Corporations and Non-Profits in the past.

Before Temple-Inland he was General Manager of Manufacturing for Marfred Industries reporting to the CEO, in charge of the three sites of the Manufacturing Division. He merged the Corrugated Plant and Folding Carton plant together into one consolidated manufacturing operation, improving efficiencies and profitability of both division P&L's. He more than quadrupled their Value Added Sales increasing gross margins and attaining over $55 million in sales.

At Gaylord Container Expert and the team implemented a Quality Transformation that made us the runner up for the Governors Quality Award for the state of Arizona, “The Pioneer Award”. They turned a plant that had been losing money into the top performing plant in Gaylord making $4 million in net profit one year. This team won the Corporate Top Performing Plant award for Gaylord for 4 straight years during hi 6 year tenure there out of 26 plants.

Dr. Box has spoken at National and Local Conferences for RISI, Expert's Firm, Institute of Packaging Professionals, American Society for Quality, South Texas Manufacturing Association, University of Texas Pan American, South Texas College, Manufacturing Summit and many others.

As President and Chief Consultant of a consulting firm, Expert has done Expert Witness with his most recent project saving the insurance company over $1 million. He is also a packaging design and branding expert for Packaging Launch.

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brand valuation

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business analysis

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business process management

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business process re-engineering

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business strategy

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business valuation

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change management

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continuous flow manufacturing

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enterprise resource planning

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factory management

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flexible manufacturing

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human-factors industrial design

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industrial engineering setup time reduction

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inventory management

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job shop operations

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maintenance management

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manufacturing cost control

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manufacturing facility design

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manufacturing process development

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manufacturing productivity

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manufacturing profitability

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manufacturing resource planning

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market trend

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marketing brand management

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materials management

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mergers and acquisitions

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online branding

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operations management

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organization redesigning

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package cost reduction

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package manufacturing

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packaging machine performance

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packaging material system

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packaging-material management

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plant management

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process optimization

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product management

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productivity measurement

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quality management

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strategic branding

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strategic management

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strategic marketing

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strategic planning

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total quality management

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world-class maintenance


Show Secondary and Basic Areas of Expertise
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Phoenix, Arizona;  Mesa, Arizona;  Glendale, Arizona;  Scottsdale, Arizona;  Chandler, Arizona;  Tempe, Arizona;  Gilbert, Arizona;  and Peoria, Arizona.

Often requested
with this expert:

Lean Manufacturing, Constraint Analysis/ Resolution, New...
Lean Manufacturing, Kanban
Green Energy Controls, Automotive Manufacturing,...
Lean Manufacturing Engineering and Production Systems...

Education:
Year   Degree   Subject   Institution  
1999   3.95 GPA (BSBA Degree Not Completed)   Business Administration   University of Phoenix  

Work History:
Years   Employer   Department   Title   Responsibilities

2010 to

 

(Undisclosed Consulting Company)

 


 

President

 

President and Chief Consultant. Keynote Speaking, Training, Expert Witness and Consulting on Packaging, Manufacturing, Organizational Improvement, Lean Six Sigma and more.

2010 to

 

(Undisclosed)

 


 

President

 

Run a recruiting and Human Resources services company.

2008 to

 

(Undisclosed)

 


 

President

 

Run an industry association for paper based packaging with over 4,000 members.

2007 to 2010

 

Temple-Inland

 

International Group

 

General Manager

 

 Manage Plants in the US and Mexico  Full P&L and Budgeting Responsibility  Increased Value Added Sales by 232%  Improved Profits by over $3 Million in 2009  Highest Productivity in the History of the Plant  Improved OHSA Recordable Rate from 8.4 to 0.75  Reduced Lead Times by 85%  Expanded sales into Central America  Improved On Time Delivery From 92% to 99.3%  Implemented Lean Six Sigma  Increased Selling Margins 34%  Improved Net ROI by 91%  Reduced Tooling Cost by 40%  Reduced Labor by over $1 Million

Asked by the Vice President of the International Group to turn around the three operations in South Texas and Northeast Mexico. These operations had declining Sales, Contribution Margin and Profit. These operations were near the bottom of the company out of 64 plants in Profit, Safety, Cost of Goods Sold, Productivity, Waste, and Quality. My team choreographed one of the best turnarounds in Temple-Inland history. This turnaround included ceasing operations in Nuevo Laredo, Mexico and adding manufacturing capabilities to the facility in Reynosa, Mexico. My operations earned the only Strong rating ever given by Temple-Inland for Financial Audit results and one of the few Strong ratings ever given for Safety Management System Audit results. Temple-Inland is the third largest manufacturer of Corrugated Packaging in North America and was voted Most Admired in Fortune Magazine three years in a row.

1999 to 2007

 

Marfred Industries

 

Manufacturing Division

 

General Manager of Manufacturing

 

 Created Multi-Divisional Strategic Plans  Full P&L and Budgeting for Two Divisions  Managed Folding Carton and Corrugated Divisions  Directed Inside Sales for the Distribution Division  Saved over $750,000 in Net Purchases Per Year  Saved over $400,000 In Labor Per Year  Led Folding Carton Division to Profitability  Opened the Structural and Graphic Design Center  Created a World Class Corrugated Operation  Reduced Folding Carton Lead Times by Over 60%  Improved Productivity in Corrugated by 18%  Increased Productivity in Folding Cartons by 26%  Implemented Kaizen, Kanban, 5S, SMED and TOC  Implemented Lean Manufacturing and Deming  Formed Comprehensive Vendor Management System  Improved Vendor On Time Delivery From 93% to 99%  Reduced Folding Carton WIP by 77%

Chosen by the CEO to assume leadership and turn around the performance of the struggling Folding Carton Division in September 2004. Challenged by the CEO to assume control of the Distribution Division Inside Sales Group in September 2006 to improve sales and customer focus in order to turn declining annual sales into sales growth. Led the Folding Carton Division to profitability and beat industry averages in sales growth in distributed products. Installed In-House Graphic Design and Computer to Plate Systems to reduce lead times and improve margins. Utilized Vital Statistics to create teams to improve performance in weak areas. Marfred Industries is a $75 million independent family owned corporation. Marfred Industries manufactures Corrugated Boxes, Folding Cartons, Litho Labels, Ink, Printing Plates, cutting dies, and has in-house graphic design, structural design, branding, and marketing. They also distribute thousands of packaging and janitorial supplies through their Distribution Division. (www.marfred.com)

 Exceed TAPPI Excellence Goals for Productivity  Exceed TAPPI Excellence Goals for Waste  Full Divisional P&L and Budgeting Responsibility  Increased Value-Added Sales by $2.1 Million

Selected to be the General Manager by the CEO to lead the $30 million Corrugated Division to “World Class” status. Doubled the size of the operation and created one of the newest state of the art facilities in North America making strong profits in a down economy.


1996 to 1999

 

Smurfit-Stone Container Corporation

 

Container Division

 

Quality Assurance Manager

 

 Nominated for Corporate Chairman's Award 1998  Nominated for Project XV Sales Award 1998  Employee of the Year 1998  Co-Wrote ISO 9001 Procedures  Achieved ISO 9001 Registration for multiple Plants  Lead ISO 9001 Quality Auditor for the Pacific Region  Safety Champion for the Southwest Region  Trained by Bain Capital on Merger Integration  Achieved and Maintained AIB – Superior  Ran the Corrugated Testing Lab (Mullen, ECT, etc.)  Account Manager for $7.5 Million in Sales  Improved Safety Incident Rate From 8.6 to 3.2

On the Smurfit-Stone Merger Mobilization team challenged with consolidating operations to save over $50 million per year. The team saved almost $100 million. Implemented the first Stone Container JIT II (Cooperative Alliance) system with a $6.5 million account in Mexico. Reduced the number of quality errors at the Glendale Plant by over 30%.

1990 to 1996

 

Gaylord Container Corporation

 


 

Lead Supervisor

 

 Best Performing Plant 1992 through 1995 (26 Plants)  Finalist for the Governor's “Pioneer Award” for Quality  Process and Procedure Training Manager  Assistant Design Engineer  Improved Safety Incident Rate from 15.7 to 4.8  Outstanding Employee Award

Started up a new Specialty Sheet Plant. Ran Corrugator, Flexo, Diecutting, Finishing, Shipping, Sheet Plant and Maintenance Departments simultaneously at two manufacturing and distribution facilities. Supervised three Foremen and over 60 employees while directing all plant training. Gaylord Container was a $1 billion corporation that is now part of Temple-Inland. This is a Union facility. (www.Temple-inland.com)


Career Accomplishments:
Associations/Societies

Appointed to the “Advisory Board” of Paperboard Packaging Magazine in 2010; Founded the Expert's Firm in Nov 2008 - recruited 4000+ members in over 30 countries; Director – Expert's Firm Expo 2010 “Leading World Class Performance;” 2009 – 2010 President of the Board of Directors, South Texas Manufacturers Association; Leader of the 2010 Strategic Planning Committee to Create the new Vision, Mission and 3 Year Plan; Packaging, branding and manufacturing expert for worldwide Packaginglaunch.com Website (2009 - 2010); 2008 - 2010 Member of the Board of Directors of the United Way of South Texas; 1999-2000 Member of the Board of Directors for Tucson Transatlantic Trade Holding Group; Senior Member of the American Society for Quality (ASQ) – Customer Supplier Division; Vice-Chairman of Administration for the ASQ Customer-Supplier Division (Fiscal 1999); Vice-Chairman of Membership for ASQ-Customer Supplier Division (Fiscal 2000); Track Manager – ASQ-Customer Supplier Division Annual Conference, October 1999; Oversaw the Bylaws Committee, Examining Committee and the Financial Auditing Committee; Member of the ASQ-Customer Supplier Division Strategic Planning Committee (2000); Member of the Technical Association for the Pulp and Paper Industry TAPPI (1998).

Licenses/Certifications

Certified Quality Engineer; Certified Quality Manager; Certified Quality Auditor; ISO 9001 Lead Auditor.

Awards/Recognition

Best Achievement of Organizational Improvement in Manufacturing Award 2009 - Given by the Six Sigma and Business Improvement Awards; Employee of the Year - Smurfit-Stone 1998; Best Performing Plant Award - Four Consecutive Years - Gaylord Container; Runner Up - Arizona Governor's "Pioneer Award for Qualty;" Nominated for the Stone Container Chairman's Award (out of over 30,000 people); Nominated for the Stone Container Value Added Sales Award.


Publications:
Publications and Patents Summary

Invented a Recyclable Corrugated Pallet. He is also the author of several journal articles and has presented at numerous conferences.


Consulting Services:
Selected Consulting Examples:
  • Expert' last Expert Witness consulting project saved the client over $1 million. It was a case where a building fire damaged manufacturing machines and equipment. He determined Fair Market Value, Cost to Build (New), Cost to Rebuild and Assessment of equipment condition and value prior to fire.
  • He has done Consulting projects with Investment Banks. One was a determination of what potential consolidation savings could be attained by two Fortune 1000 Packaging Companies merging. What redundant capacity could be removed and what profit improvement could result in the combined scale of the companies.
  • He is currently working on a Market Feasability study to determine which of three markets would be the best to open a brand new state of the art Corrugated Plant (with Corrugator).
  • He has done Keynote Speaking for companies and associations.
  • He has done training on Profit Improvement, 5s, Lean Manufacturing, Lean Six Sigma, Quality Improvement, Safety Leadership, OSHA, Forklift Training, Hiring the Best, Cost Control, Value Added Sales, Consultative Sales, Enterprise System Set Up and much more.
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:
Expert Witness Experience Summary:
He has been involved in labor litigation, corporate litigation, trained on antitrust and his most recent Expert Witness project savet the client over $1 million. A manufacturing plant burned down and there was a custom one of a kind machine (similar to others) that was burned up. Expert had to determine fair market value, build value, rebuild value, etc. which resulted in reducing the exposure of the Insurance Company by over $1 Million. He is very familiar with fires, floods, etc. and can help companies justify their values or help insurance companies avoid being cheated by companies exaggerating their claims.
Recent Litigation Client Requests:
  • Expert for consulting on lawsuit against integrated containerboard and corrugated container manufacturers.
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
1997 to 1998   Mexico   Formed a Cooperative Alliance as an In-Plant with a $6.5 million customer. He handled the cust opers purchasing, order scheduling, and any issues with customs, accounting, logistics and more. He had an FM3 Work Visa.
2007 to 2010   Mexico   He ran a Manufacturing facility and a Distribution Center for Temple-Inland in Reynosa, Tamaulipas, Mexico and Nuevo Laredo, Nuevo Leon, Mexico. He shut down the Nuevo Laredo facility after just over a year to consolidate operations in Reynosa. He had an FM3 Work Visa for the three years he ran these operations.

Language Skills:
Foreign Language   Description
Spanish   He can get by taling about business and manufacturing in Spanish but has a rather limited vocabulary.

Market Research:
He stays current on linerboard and medium pricing as well as trends on OCC and supply and demand indicators.

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 trained these topics at national conferences: Leading World Class Performance, Lean Manufacturing, Performance Improvement, Improving Profitability, Building World Class Teams, Value Added Selling, Hire the Best..Fire the Rest, The Future of Quality in Corrugated and more.

He has also developed training programs for Safety, Quality, Productivity, Lean Manufacturing, 5S, Profit Improvement, Hiring, Consultative Sales, Value Added Sales, Box Manufacturing, Packaging Sales, Waste Reduction, Machine Set-Up, Diecutting, Printing and more.

Supplier and Vendor Location and Selection

He knows most of the suppliers and vendors in the Corrugated and Folding Carton industries and has relationships with many of them.


 

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