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Summary
This Manufacturing & Operations Executive is a leader with experience leading global cross-functional teams to solve complex problems to achieve targets, create new opportunities, and develop a continuous improvement culture that consistently delivers results while developing talent and growing employees at all levels. He uses collaborative leadership combined with clear metrics and lines of responsibility to achieve breakthrough performance. This Manufacturing & Operations Executive has extensive Wire Harness Operations experience first as a leader for the electrical distribution division of Lear responsible for wire harness plants including extensive CI leadership and as the Director of Operations for Aptiv producing parts for Wire Harness assembly plants.
Highlights
- 25+ years of experience Automotive supplier – OEM & Tier 1
- 10+ years with Wire Harness and Components
- P&L Operations Management
- 3PL and Supply Chain Management
- Executive Team Leadership
- Acquisitions and Mergers Management
- Mentorship and Talent Development
- Expert in International Kaizen Leadership
- Cellular Manufacturing Expert
- Experience in Low-Volume and High Mix Operations
- Lean Six Sigma Black Belt
- Certified Supplier Quality Engineer by GM
- Cross-Functional Leadership Solving Complex Problems
Relevant Accomplishments
- 4 years in electrical distribution division working with wire harness plants and with the factories making components for wire harness (seat memory modules, terminals, pins, fuzes, etc.). Reviewed and worked projects in over 30 wire harness plants world-wide. Reviewed and worked projects in all 6 terminal and connectors plants at Lear. 2 years in Seat division, a major consumer of wire harnesses
- Director of US Operations for Aptiv Responsible for 6 factories, 2 distribution centers, 1100 employees, and $660M annual revenue for Wire Harness assembly plants producing:
- Terminals, Buss bars, Fuses, and Grounds used in wire harnesses
- Connectors for wire harnesses
- Plastic resin used in connectors and junction boxes
- Junction boxes and Fuse boxes (tier -1)
- Silicone seals for wire harnesses and gaskets for wire harness connectors
- Specialty connectors and solder for on-glass connections (examples: the wire that defrosts the rear window, or the cameras and sensors that are connected to the front windshield)
- Worked 6 years at CEVA Logistics
- Worked and did projects in multiple sequencing and kitting centers that receive bulk quantities of wire harnesses from the suppliers and delivered them Just-In-Time (JIT) and Just-In-Sequence (JIS) to the vehicle assembly plants, some of which were delivered to the point of install
- Visited and analyzed 25 vehicle assembly plants world-wide and studied the installation of wire harness in the frame, the doors, headliner, engine, front and rear fascia, etc.
- Subject matter expert for optimizing logistics management including warehouses, cross docks, distribution centers, sortation, subassembly, kitting, just-in-time (JIT) and just-in sequence (JIS), inbound to manufacturing, and in-factory logistics, including hundreds of products such as wire harnesses
- Experience across automotive wire harness manufacturing and assembly including assembly, wire, terminals, connectors, and silicone seals and gaskets – reviewed 35+ wire harness assembly plant. Negotiated union collective bargaining agreement (CBA) for 5 wire harness components factories in US
- Increased machine uptime, reduced WIP inventory, and dropped past-due by 90% at aerospace manufacturer. Improved flow of material through receiving, processing, and distribution for manufacturer of epoxy paint. Designed factory layout for manufacturer of next-generation rechargeable batteries.
- Implemented lean in products and processes design (LPPD), Design for Manufacturing and design for Assembly (DfM/DfA) and Value Added/ Value Engineering (VA/VE)
- Turned around of $600M, five-factory division of automotive parts supplier to record margins in one year
- Processes design for new product introductions (NPI) of hi-voltage wire harness, battery management, power conversion, and electrical distribution for High-Voltage (HV), Hybrid, and Electric Vehicles (HEV)
- Reduced capital expense from $6 million to $2 million for high-volume manufacturing line and reduced footprint from 3500 ft2 to 1000 ft2 without increasing operational costs
- Lowered total cost and awarded transfer of circuit board assembly from China to union factory in US
- Integration of acquired company – redesigned 21 manufacturing processes; reduce area 60% and labor 50%
- Reduced external quality errors from 24 Ppm to 11 Ppm across 14 tier-1 plants in North and South America
- Reduced expedited freight costs from US$11M to $6.5M in six months for factory in Mexico
- Joint Intelligence Operations Officer and military liaison to law enforcement at the 1996 Olympics and Para-Olympics in Atlanta and immediate response after the bombing at Olympic Park
- Implemented Managing for Daily Improvement (MDI) at several manufacturing and logistics locations
Roles
- Director Of Operations
- Global Head, Business Process Excellent and Project Management Office
- Director of Continuous Improvement for Electronics, Electrical Distribution and Electro Mechanical
- Sr. Quality Engineering Manager
- Business Unit Manager
- Senior Officer (Lt. Colonel) US Army
Request Expert / Similar Expert
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