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Summary
This Global Manufacturing Operations Consultant is an operations executive with over 20 years of experience. Expertise in operational performance turnarounds and planning, lean manufacturing, continuous improvement, and team leadership makes him an ideal candidate. Over the course of his career, he has developed a robust portfolio of success stories and turnaround improving operational performance and profitability in global manufacturing for a diverse array of products and industries. Track record of building synergies as a champion of cross-functional integration and continuous improvement. This Global Manufacturing Operations Consultant is known for creating collaborative customer alliances to enhance service value and expanding revenue. Respected leader of a global workforce of ~1,000 people, fostering cultures of safety, quality and a self-assessing, self-correcting repeatable operational excellence review process. This Global Manufacturing Operations Consultant has extensive experience improving operations in low volume and high mix environments with much of this experience in wire harness operations.
Highlights
- 20+ years of Operational Excellence Experience
- P&L Operations Management
- Strategic Business Planning & S&IOP Leadership
- Global Supply Chain Expertise & Agility
- Executive Team Leadership & Strategy Deployment
- Acquisition Synergy, Integration & Operation System Conversations
- Portfolio Development & Growth (Organic & New Growth)
- Process Innovation/Change Management Continuous Improvement Management Quality Assurance & Safety
- Strategic Workforce Development
Relevant Accomplishments
- Most resent: As the Global Operations & Chief Quality Officer at Zhejiang Inventronics Optoelectronics Company, he established two new factories, low volume/high mix, in India and Mexico during the COVID pandemic and the global supply chain crisis period. Tripled production capacity in the India plant by implementing a second production line, second shift and strategic local sourcing. In addition, overall worldwide, strengthened quality, reducing the parts per million rate by 97.7%, by strategizing and executing targeted improvement plans and new best practices globally.
- As a strategic business partner in driving growth, he and his team achieve 600% sales growth for the factory in India through collaborative planning with sales leadership (S&IOP). He has a long history of building customer and internal cross-functional partnerships, as the keys to thriving business performance and profitability.
- His experience with both low/complex and high mixed volume is most relevant to this position. John’s operational leadership and factory turnarounds as a global industry manufacturing leader include companies such as Yazaki North America Operation, ATC Drivetrain, United Technology Aerospace Systems, Veeder-Root and Operations. A few relevant highlights:
- Most relevant to this position: Yazaki North American Operations. A manufacture of electronic system solutions that included processes from wire extrusion, wire harness, plastic injection molding, progressive metal stamping, printed circuit board/SMT assembly to mechanical assembly of intelligent power module, fuse junction blocks to wire harnesses subassemblies. Specific accomplishments here include:
- Established South Georgia as a benchmark for all Global Yazaki and winning the Georgia Oglethorpe award for operational excellence presented by then Governor Sonny Purdue
- Increased on time delivery (Including PO line items) to greater than 99%. Product of a solid S&IOP process.
- Reduced manufacturing scrap from 7% of sales costing $3,000,000 annually to 0.8%.
- Eliminated the dependence of overtime with the exception occasional overtime due to service/warranty builds and parts availability.
- Improved products on quality hold from 15.4% of monthly sales to 0.5% of monthly sales by implementing clear root cause analysis and corrective action and a < 72-hour quality disposition time limit.
- Increased inventory accuracy from 50% to greater than 95% by integrating “Just-in-Time, Just-in-Place” physical inventory system base, resulting in 0.2% adjustment to monthly sales (S&IOP).
- Minimized cost of raw material work in process from $65,000 to $6,000 per line by instituting lean manufacturing concepts in the PCBA/SMT operation.
- Improved internal quality of 20kppm internal/10kppm external to 1,500ppm internal/10ppm external while sustaining zero defects for many automotive customers.
- Created vertical profit and loss system to analyze platform targets and margins, integrating three-year technical and manufacturing road maps to reduce defects, improve reliability, and decrease reworking. Defect/rework free quality initiatives.
- Integrated volume-based flexible line/cell (Play booking) concept to maximize operational productivity and efficiency, resulting in significant decreases in labor/floor space requirements.
- Reduced monthly average of 25part shortages to less than 4 in the PCBA/SMT process.
- Lead several complex enterprises and product issues that included a long standing issue with wire insulation thickness irregularity that plagued one of our wire extrusion sites.
- Standardized Global Best Practices for both Enterprise and Product Process development. As part of the John Silva brand.
- Returned factories to profitability at ATC Drivetrain in 9 months. Fastest business turnaround.
- Regained a top rating with The Boeing Company for United Technology Aerospace Systems and decreased PPM 67% across nine plants.
- Improved quality across nine sites, drove down external PPM by 86%, and lowered the open duration of outstanding corrective actions with customers, from 180 days to less than 14 at Sporlan (Parker Hannifin).
- Shortened the lead time and boosted on-time delivery (OTD) from 67% to 99%+ at below-standard cost at Veeder-Root.
Roles
- Vice President of Global Operations
- Vice President of Operational Exelence & Continuous Improvement
- Chief Quality Officer
- Vice President of Quality Assurance & Operational Excellence
- Divisional OPEX & QA Global Director
Request Expert / Similar Expert
Click “request expert” for a free initial screening call with this expert or a similar expert regarding your expert consulting needs
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