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Dean Maple - LSSBB
        Career Accomplishment Summary

                        Dean Maple
                   102 Aiken Farm Road
               Pickens, South Carolina 29671
                       864-878-1799
                  demap102@charter.net


3/18/2010                Dean Maple            1
Index
           Summary of Qualifications
           Key Accomplishments & Supporting Data
            –   Materials/Prod. Control
            –   Manufacturing
            –   Supply Chain
            –   Project Management
            –   Systems Implementation
            –   Problem Solving
            –   Plant Management
           Certifications
           Performance Reviews & References
3/18/2010                         Dean Maple        2
Career Summary
           Extensive experience assessing operations, improving
            performance and reducing costs.
           Proven experience in Supply Chain Management and
            Execution and Lean Manufacturing resulting in
            savings in excess of $1.5 million dollars.
           Key implementation experience with SAP and
            Manufacturing Execution Systems implementation.
           Committed to quality with certification experience in
            ISO 9000, QS 9000 and SPC.


3/18/2010                        Dean Maple                         3
Certifications – Lean Six Sigma Black Belt




3/18/2010               Dean Maple                4
Letter of Reference


      Borg Warner:
     Mr. Dave Baker
       Human Resource
       Manager. Phone
       864-985-5141




3/18/2010                  Dean Maple   5
Letter of Reference - Mr. Wayne Smith Former VP
            Manufacturing for Ryobi, Current Exec. VP Rival-
            Holmes Group
      T h e H o lm es G ro u p
      O n e H o lm es W a y
      M ilfo rd , M A 01 7 5 7

      D e ce m b e r 2 0 , 2 0 01

      T o W ho m T his M a y Co n ce rn :

      P le a se a cce p t th is d o cu m e n t a s a re fe re n ce fo r M r. D e a n M a p le. I w o uld re co m m e n d th a t a n y o n e
      in th e a re a s o f b u sin e ss, m a n u fa ctu rin g , o r e d u ca tio n u tilize M r. M a ple 's ex te n siv e k n o w le d g e a n d
      e x p e rie n ce . H e is a sk ille d , m a n a g e r, co m m u n ica to r, a n d le a d e r, p a rticu la rly in th e fie ld s o f
      o p e ra tio ns, b u sin e ss, a n d su p p ly ch ain .

      I h a v e k n o w n M r. M a ple fo r n e a rly te n y e a rs. In th e 9 0 's h e w o rk e d fo r m e a s a n e x e cu tiv e
      h e a d in g a v a rie ty o f a re a s fro m o p e ra tio n s to m a te rials to su p p ly ch ain . In m a n y ca se s h e a cte d
      a s m y "b a ck u p " a n d th e m a n a g e r I m o st d e p e n d e d u p o n . His im p le m e n ta tio n o f n e w a n d "u p to
      d a te " p ro g ra m s a n d te ch n iq u e s sa v e d th e co m p a n y tho u sa n d s o f d olla rs. H e is a d e p t a t
      co m m u n ica tin g a n d p re se n tin g o n th e fa cto ry flo o r, in th e cla ssroo m , o r in th e b o a rd roo m .

      H e is a h a rd w o rke r, a p e o ple p e rso n , a n d h is eth ics a re u n q u e stio n a b le.

      P le a se fe el fre e to co n ta ct m e to discu ss a n y d e ta ils o f th is re co m m e n d a tio n .

      S in ce re ly ,

      W a y n e F . S m ith
                                      Phone: 660-885-5564 (X168)
                                      Cell:     816-804-6739
                                      E m ail: w fsmith@ theholm esgroup.com




3/18/2010                                                                            Dean Maple                                                    6
Performance Evaluation - Carl Klebe VP Operations Ryobi
     Review conducted on move from Manufacturing to Material
     responsibilities. ( 1996 - 1997)

     More important to the decision to place Dean in the Materials
       function are the following aspects of his performance during the
       two years prior to the decision. First he consistently
       demonstrated the ability to deal with change and new situations.
       Second, he was consistently willing to take responsibility for and
       leadership of all assignments. He demonstrated both experience
       and a solid understanding of Production Control and Materials
       Management He is willing to take personal risks to accomplish
       changes needed to move the plant operations forward. He is
       willing and does put in the extra effort required by challenging
       and critical assignments

3/18/2010                         Dean Maple                                7
Materials/Prod. Control
     Initiatives
           Assembly line uptime initiative
           MRO - Integrated Supply Implementation
           Vendor Managed Inventory Implementation
           Kanban/Lean Manufacturing Implementation
           Pricing and Source Negotiations
           Logistics initiatives




3/18/2010                    Dean Maple                8
Materials/Prod. Control Initiatives
     Assembly Line Up Time
                                                                                    Hours
           Situation: Significant
            assembly line interruptions for                  35
            late delivery, or misplaced                      30
            inventory.                                       25
           Actions: Analyze root cause,                     20
            utilize fishbone analysis and                    15
            implement Kaizen team.                           10
           Results: Significant reduction                    5
            in assembly line downtime.                        0




                                                                                     Jan-97
                                                                  Sep-96

                                                                           Nov-96




                                                                                                       May-97
                                                                                              Mar-97
                                   Percent
         Year       1996    1997   Change
      Inventory
     Accuracy       104.8   77.5   -26.05
      Inventory
                                             Downtime hour results comparison
     Delivery &                              1996 vs 1997. DT Hours costed at
     Availability   246.9   88.7   -64.07
                                                $400/hr savings of $72,400
3/18/2010                                       Dean Maple                                                      9
Materials/Prod. Control Initiatives Ryobi
     MRO - Integrated Supply                Situation &
                                                                Tasks
           1/7/97 Current Inventory $ 1.3 million ( not including
            maintenance)
           1996 Inventory Turns = 1
           1996 # of vendors = 700 (Includes capital equip.&
            contractors )
           1996 Purchases = $ 4.8 million(less capital equip.& Const.)
           Over $400,000 of current inventory has had no activity since
            December 1994.
           Stockouts still shutdown operations waiting on vendors to
            supply from blanket orders.
           1996 cut over 10,000 Purchase Orders & Processed 8,875
            Invoices
3/18/2010                           Dean Maple                             10
Materials/Prod. Control Initiatives   Vision
     MRO - Integrated Supply             Statement
           To eliminate the MRO products inventory, daily
            purchasing and inventory management function of this
            inventory for our plant, focusing on the following key
            benefits:
           Improved cash flow.
           Reduced cost of products purchased.
           Reduced inventory carrying costs.
           Improved focus on core business.
           Reduced purchase transaction costs.



3/18/2010                          Dean Maple                        11
Materials/Prod. Control Initiatives                Decision
     MRO - Integrated Supply                           Agreement
                                                      Implemented
           Proposal Summary
             – Use up active inventory.
             – Guaranteed savings 4% hard cost in first year.
             – Projected annual savings breakdown.( D.M.)
                 1st Year $ 376,610
                 2nd Year $ 298,610
                 3rd Year $ 233,810
             – Actively drive down Ryobi Owned Inventory
             – Implementation throughout facility in 1997.
             – Key to all this is a Partnership Relationship

3/18/2010                          Dean Maple                       12
Results
     Materials/Prod. Control InitiativesSince Integrated SupplyTarget Start
                                                  Inventory Trend

                                                   Date Reduced
     MRO - Integrated Supply                by $561,224 in Acct 1607
                                            Eliminated 1605 $ 65,000
                                                                                                  Total reduction project to date is
                                                                                                              $626,224
     Inventory reductions continued through 1999.
     With cost savings meeting agreed objectives.
                                  1607 MRO Inventory Account Stock Status ( Weekly Inventory)




            $1,400,000


            $1,200,000


            $1,000,000


             $800,000


             $600,000


             $400,000


             $200,000


                   $0
                     Beg.   15-   29-   10-   21-    2-   13-   25-    6-    17- 28- 11- 23-       4-     15- 27-   8-   21-
                            Feb   Mar   May   Jun   Aug   Sep   Oct   Dec   Jan- Feb- Apr- May-   Jul-   Aug- Sep- Nov- Dec-
                                                                             98   98   98   98     98     98   98   98   98


3/18/2010                                                  Dean Maple                                                                  13
Materials Initiatives
     V M I - Fasteners

           Situation: Delivery Issues, High Inventory, Escalating
            Pricing, Product Quality
           Actions: Single source supply, on site inventory
            ownership, Kanban delivery to line side, elimination
            of returns to stock.
           Results: Elimination of company owned inventory $
            100,000 reduction, elimination of delivery problems,
            purchase upon consumption of
            product.Implementation of Kanban pull.Reduction in
            headcount 2 employees.Elimination of returns to
            stock.
3/18/2010                        Dean Maple                          14
Focused Efforts on reduction of
     Materials Initiatives                                          stock transactions and improved use
     V M I - Fasteners                                                     of Kanban point of use
                                                                            replenishment stocks.

                                       % of Total Pcs Returned to Stock Each Week


                 35.00%
                 30.00%
                 25.00%
       Percent




                 20.00%
                 15.00%
                 10.00%
                  5.00%
                  0.00%
                           7-   11- 15- 22- 26- 31-        5-      9-   13- 18- 22- 27- 31-      7-  11-
                          Dec- Jan- Feb- Mar- Apr- May-   Jul-    Aug- Sep- Oct- Nov- Dec- Jan- Mar- Apr-
                           97   98   98   98   98   98     98      98   98   98   98   98   99   99   99
                                                                  Week


                                                        Percent      Log. (Percent)


3/18/2010                                           Dean Maple                                          15
Materials Initiatives: Kanban

           Plastic Omnium: Implemented Internal Kanban pull
            between stocks warehouse. Improved inventory accuracy
            from an average 25%monthly error ($400,000) to an
            average of 2.5%.
           Borg Warner: Expanded the external demand pull Kanban
            system to include Hyundai. Implemented computerized
            Access database system for managing Kanban
            communication to suppliers.
           Ryobi: Implemented external demand pull Kanban through
            the following areas: Plastics, Fluids, Packaging, Fasteners,
            and Motor materials. Resulting in a reduction of Raw &
            Wip inventories of $2 million dollars.

3/18/2010                          Dean Maple                              16
Materials Initiatives
     Price & Source Negotiations

           Annual Contract Negotiation:
            –   Flat rolled steel purchases * $ 1.6 million dollars
                contract for stamping materials. Established product
                family group pricing and a vendor owned finished
                inventory daily shipping bank.
            –   Aluminum Die Cast ingot purchase contracts negotiated
                based upon futures metal market projections, annual
                purchases in excess of $5 million dollars. Realized a
                $170,000 annual savings.



3/18/2010                          Dean Maple                       17
Materials Initiatives: Logistics

           Plastic Omnium: Implemented a materials/logistics system, SAP
            4.6, major improvement to customer suppliers rating for logistics
            functions.
           Borg Warner: Implemented cost savings on transportation with the
            use of Milk Runs, single source transit & customs clearance of $
            250,000.
           AFCO: Expanded Milk Run, returnable container programs to
            expand company program for elimination of waste and refuse
            disposal at the plant. Estimated annual savings were $ 100,000.
           Ryobi: As a component of my procurement responsibilities I
            studied routing of Far East purchases. Finding that 85% of all
            purchases came via the most expensive routing the routing was
            changed and pricing negotiated with ocean carriers resulting in a
            $250,000 savings.

3/18/2010                             Dean Maple                                18
Plastic
     Logistics – Inventory Mgt.               Omnium


                                 First Objective: Make
                                  it accurate.
                                  –   Establish Control
                                  –   Train the employees
                                  –   Cycle count
                                  –   Focus on corporate
                                      objective of <3% error
                                      in inventory.




3/18/2010            Dean Maple                                19
Plastic
     Logistics – Inventory Mgt.                                                 Omnium


                   Duncan Month End Inventory Results                         Second
                                                                               Objective: Find
      $3,000,000
                                                                               ways to reduce
      $2,500,000
      $2,000,000
                                                                               it.
      $1,500,000
                                                                               –   Procurement/
      $1,000,000
                                                                                   Planning
                                                                                   Management
       $500,000
             $0
                                                                               –   Supply Chain
                                                                                   Management

              De -0 4
                       v

              Fe -0 4




               Ju 0 4
              Ap - 04
              Ma - 04
                       n




                       n
                 Au l




              Au l-04
              Se - 04
              Oc - 04


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              Ma 4
              Ja e c




              J u -04
                 Se g
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                     pt
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              No - 04
                       t
                      y

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                  Oc
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                  r- 0




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                                                                                   Transportation
                 n-


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                 D




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                 n

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                 b




                 g
                 p
                 y




                 t
                                                                                   Management
                   Total Inventory    2 per. Mov. Avg. (Total Inventory)


3/18/2010                                         Dean Maple                                        20
Logistics – BMW Supplier Rating


                                  Best Result for
                                 Plastic Omnium
                                  Logistics Score
                                     since the
                                 beginning of the
                                 relationship with
                                 BMW, 10 years.




3/18/2010           Dean Maple                       21
Manufacturing - Initiatives ( Ryobi)

           Productivity - Die Cast Machining
           Kaizen Continuous Process Improvement
           New Product Introduction
           Motor Assembly Line Project




3/18/2010                    Dean Maple             22
Manufacturing Initiatives- Die Cast Machining Productivity

    Reduced Scrap, Reduced
    Overtime Hours Support
          Productivity




                                                           12 % improvement in
                                                       productivity acknowledged by
                                                           the VP of Operations




Focus on productivity = Reduced Secondary Labor,
3/18/2010                                 Dean Maple                                  23
Reduced Indirect & Increased Direct Labor Efficiency
Manufacturing Initiative - Die Cast Machining
     Productivity
                                              Results:
           Situation: Low                    Zero defects for nine
            Productivity, High Scrap,          continuous months(through
            High Indirect and                  project completion) with
            Secondary Labor                    major customer.
            Expenses.                         $ 100,000 Savings on cell
           Actions: Form Kaizen               reorganization.
            Team, Capacity Analysis -         Employees from Shop floor
            Study Constraints,                 part of Kaizen team for
            Implement SPC, Educate             continuos improvement.
            & Involve Employees               Sustained 10-12 %
                                               productivity improvement.

3/18/2010                         Dean Maple                               24
Manufacturing Initiative - Die Cast Machining
                            Cellular production startup of a major product
     Productivity          introduction. Constrained by process and launch
     New product startup            to market timing requirement.
                                                                          Leap Router Parts Machined

                                                         15,000




                                          Production
                                                         10,000

                                                                5,000

                                                                   0
                                                                        2-Oct           9-Oct             16-Oct      23-Oct
                                                                                                 Weeks

                                                                                Total Machined       Log. (Total Machined)



                                                                            Leap Router Parts/Hour

                                                                100




                                                   Production
                                                                 50

                                                                   0
                                                                        2-Oct           9-Oct             16-Oct           23-Oct
                                                                                                  Weeks


                                                                                   Parts per hr      Log. (Parts per hr)




3/18/2010                        Dean Maple                                                                                         25
Manufacturing Productivity Initiative - Assembly

                                            (see project mgt..)


                                          Letter of recognition
                                           for project leadership
                                           from startup, full
                                           production release,
                                           Kaizen training of
                                           employees and order
                                           fulfillment to
                                           customer.



3/18/2010                     Dean Maple                            26
Project Management - Manufacturing and
     Materials Initiatives
                  A re a             D e s c rip tio n          S itu a tio n          C o m m e n ts

               M a te ria ls :           Vendor               P e rfo rm a s a n        C o m p a n y in
              C o m p a n y:         M anagem ent &                 o n s ite            je o p a rd y o f
              A s s o c ia te d       Q u a lific a tio n     m a te ria ls a n d       s h u td o w n o f
              Fuel Pum p                                      m a n u fa c tu rin g     T o yo ta a n d
             C o rp o ra tio n                                  s u p p o rt fo r            H onda
             D a te : 9 /2 0 0 0                                   s u p p lie r          A s s e m b ly
                                                                                              L in e s
              O p e ra tio n s /      P ro je c t C a s h           Excess                  S e rio u s
             P ro c u re m e n t      R e d u c tio n o f       In ve n to ry o f          fin a n c ia l
                C o rp o ra te         in ve n to rie s .            M fg . &              c o n d itio n
            In itia tiv e R yo b i   G e n e ra te c a s h       P u rc h a s e d       o b je c tive to
             D a te : 2 /2 0 0 0         flo w fro m         F in is h e d G o o d s   e lim in a te $ 2 5
                                       e x c e s s in v.                               m illio n d o lla rs
                                                                                         e x c e s s in v.




3/18/2010                                          Dean Maple                                                 27
Project Management - Manufacturing and
     Materials Initiatives
                  Area            D e s c r ip tio n         S itu a tio n           C o m m e n ts


              S ta m p in g        L e a d C ro s s       T h e s ta m p in g          D ir e c te d to
             O p e r a tio n s       fu n c tio n a l        o p e r a tio n        n e g o tia te a n d
              O u ts o u r c e         te a m to              w e re n o              r e lo c a te th e
                  R yobi          o u ts o u r c e th e        lo n g e r           b u s in e s s to a n
             D a te :1 /1 9 9 9      s ta m p in g        c o n s id e r e d a             o u ts id e
                                     o p e r a tio n             c o re                   ve n d o r.
                                                           c o m p e te n c y              B udget
                                                                                        $ 1 5 0 ,0 0 0
               In s o u r c e      L e a d a cro s s      M a n u f a c tu r in g       R e n o v a te
            M o to r M o d u le       fu n c tio n a l       c o n tr a c t to          space, 2-
             p r o d u c tio n    te a m to lo c a te     s u p p ly m o to r s            m o n th
             R y o b i D a te :          m o to r          fo r f lo o r c a r e         tim e ta b le
                 7 /1 9 9 9        p r o d u c tio n to    c u s to m e r f o r       p u r c h a s e a ll
                                     th e fo rm e r         th r e e y e a r s         e q u ip m e n t,
                                  s ta m p in g a r e a                                      tr a in
                                                                                      e m p lo y e e s .
                                                                                           B udget
                                                                                        $ 1 5 0 ,0 0 0




3/18/2010                                      Dean Maple                                                    28
Project Management - AFCO on site
     vendor support
           Situation: Supplier selected was not able to adequately support
            component demand upon release to produce, jeopardizing
            vehicle assembly schedules at Honda, Toyota and Numi. I was
            selected to perform as the on site vendor support person in
            Detroit.
           Actions: Implemented Master Schedule, Subcontractor
            schedules, evaluated, recommended & pushed implementation
            of shop floor materials control and equipment layout changes.
            Daily productivity reporting. Visual schedule and production
            posting.
           Results:Supplier shipments on time, quality problems addressed
            and vehicle assembly line downtime avoided.

3/18/2010                            Dean Maple                               29
Project Management: Ryobi Project Cash -
     Finished Goods Team Leader

           Situation: The company was severely effected by the Asian
            banking crisis and a the difficulties of managing supply chain
            purchases for Far East finished goods purchase decisions.
            Finished Goods inventories were at an all time high of $80
            million dollars and in a cash supply crisis. An S & OP process
            was not in place nor a procurement organization separate from
            the sales & marketing organization.
           Actions: A cross functional team was formed along with a
            Consulting team from Delloite & Touche. Analysis of
            forecasting, buying practices, implementation of a master
            procurement schedule and creation of a the Demand Planning
            discipline to lead the S & OP process and create a separate
            procurement department was implemented.
3/18/2010                           Dean Maple                               30
Project Management: Ryobi Project Cash
       Finished Goods Team - Results

       A $ 30 Million dollar reduction in inventory was realized and
            enough cash generated to significantly reduce borrowing
            requirements.
           S & OP process was implemented providing discipline to
            coordinate the key functions of :

   C
            –   New Product Planning                                  C
   U                                                                  U
   S
            –   Demand Planning                                       S
                                                 Integrated           T
   T
   O
            –   Supply Planning                   Business            O
   M                                                Plans             M
   E        –   Financial Planning                                    E
   R                                                                  R


3/18/2010                           Dean Maple                            31
Project Management: Stamping Outsource &
     Motor Insource Project Leader - Project
     Description

           Stamping - Outsource the approximately 300 components
            manufactured in house to an outside supplier with the key
            criteria to complete the project in six months with no
            interruptions in manufacturing assembly schedules and
            utilize the existing work force through the end of the
            project to support building inventory banks to support the
            move.
           Motor Manufacturing- Continuing after completion of the
            stamping project, renovate the manufacturing area, install
            equipment, train new employees and deliver product to the
            customer in less than 3 months from start of project.

3/18/2010                          Dean Maple                            32
Project Management: Stamping Outsource &
     Motor Insource Project Leader

           Key Project Functions Addressed:
            – Human Resources
            – Engineering
            – Supplier Negotiations
            – Maintenance
            – Logistics
            – Planning
            – Equipment Sales and Relocation


3/18/2010                     Dean Maple        33
Project Management: Stamping Outsource &
     Motor Insource Project Leader Timeline
                        Jan-97   Feb-97   Mar-97   Apr-97   May-97   Jun-97   Jul-97   Aug-97   Sep-97   Oct-97
         Stamping
          Supplier
       Negotiations
          Project
         Release -
         Stamping
        Component
       Transf er Plan
         Executed
         Equipment
       Transf erred
         Stamping
           area
        renovation
           Motor
       Component
         Supplier
       Negotiations
       Eng, &Equip
           Req.
       Executed &
         Installed
       Employees
        Trained &
        Production
          Startup




3/18/2010                                             Dean Maple                                                  34
Project Management: Stamping Outsource &
     Motor Insource - Project Results

      Projects on Time :
      No Interruptions in Manufacturing Assembly - Stamping
       Project:
      Projects within Budget:
             Stamping $150,000Budget - Came in under budget and generated
              over $500,000 in income from the sale of the equipment.
             Motor Project $150,000 Budget - Came in under budget
      Employees:
             Stamping - Excellent cooperation all provided jobs who wished to
              work, 3 senior employees retired.
             Motor Project: All trained, staffed on schedule and beat previous
              production rates & quality standards.
3/18/2010                             Dean Maple                                  35
Automotive Launch Project – BMW E53 Mu
     Facelift – Successful “Digital Launch” at BMW
                                                             E53 Face Lift Timing Plan                                                                                                Planned Finish Date
                                                             Area: Logistics - Dean Maple                                                                                             Important elements not fulfilled - danger of missing due date
                                                             Revision Date/CW: May 23 2003 - CW 21                                                                                    Some elements not fulfilled; counter measure needed to regain planned timing
                                                             Revision Level: A                                                                 According to plan
                                          Months 2003 January             February       March         April         May          June          July       August     September       October
                                        Calendar Week 2 3 4              5 6 7 8       9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43


            Verification of PTO Releases (TOD)          100% Complet e


            Verification of PS1 Releases                                                    0% 100%


            Verification of PS2 Releases                                                                                           0% 50% 100%


            Verification of AS Releases                                                                                                                                          0%




            Deliver PTO/KEX Parts                                  10% 15% 20% 40% 50% 60% 70% 80% 90%        no issues

            Deliver PS1 Parts                                                                             0% 20% 60% 70% 100%


            Deliver PS2 Parts                                                                                                                    20% 30% 40% 50%


            Deliver AS Parts                                                                                                                                                                    0%




            Elimination of EDI Errors                          0% 20% 20% 20% 30% 40% 50% 50% 50% 50% 60% 60% 60% 70% 70% 70% 70% 70% 70% 100%                                                       complet e - no er r or s




            Validation of Shipping Rack Allotment                                      0%   0% 10%       Waiting to determine pro to feasability fo r density




            Run-out Plan                                                                                  0% 10% 20% 20% 20% 30% 30% 30%              Initial run o ut plan needs to be drafted and appro ved - P riscilla/A nn

            Production Inventory Runout Management                                                                                                     0%




            Current E53 Front Service
            Validate layout/location w/Process Team                                                                                                         0%


                   Run-out Plan (one time buys, etc.)                                                                                                                                      0%


                      Management of new service line


                                                          PTO/KEX 52                                          PVS1 64                              PVS2 43                                                    ANLAUF 134            SOP 400 Vehicles per day




3/18/2010                                                                                             Dean Maple                                                                                                                                      36
Systems Implementation
           SAP 4.6 – Plastic Omnium:                                 Monthly Inventory Adjustment % of Ending Inventory
            SAP had been installed for 5
            years but never properly used             35.0%           32.9%

            for procurement, inventory                30.0%
                                                              25.9%
            management and execution.
                                                      25.0%                        21.5%
            Implemented 4.6 in March
            2003. Key functions and                   20.0%




                                                  %
            responsibilities executed for a           15.0%
                                                                                                  9.9%
            successful implementation.                10.0%                                                     6.5%       6.5%
            Immediate results achieved                                                                                            5.02%
                                                      5.0%
            with inventory accuracy.
                                                      0.0%
                                                               Jan     Feb          Mar           Apr           May        Jun     Jul
                                                                                                 Month




3/18/2010                                     Dean Maple                                                                                 37
Computer Systems Implementation
           SAP 4.6 – Plastic Omnium: Procurement, Inventory Control,
            Transaction Control – Material Movement, Production Reporting,
            Customer Delfor Management, EDI
           SAP 4.0 Ryobi: Warehouse Management, Master Production Planning,
            Master Procurement Planning, Material Movement, Sales Forecasting,
            Sales & Operations Planning Production Reporting.
           Synquest Material Execution System – Ryobi – Shop floor control for
            work center loading and detail planning. Complement to SAP.
           Early career projects include: Order entry, shop floor control




3/18/2010                             Dean Maple                              38
Systems Implementation                 Plastic
                                           Omnium

            SAP Version 4.6
      Planning Execution
      Stock Coverage
       Analysis
      EDI Requirements
       Communication
      ASN Communication
      BMW SPAB Interface
      BMW Technical Order
       Data Management




3/18/2010                     Dean Maple          39
Systems Implementation                                                  Plastic
     2005 SAP Upgrade                                                       Omnium

             SCOOP Project               Led the project initiative for
                                          implementation of BMW related functions
     •      Supply Chain                  for the Duncan, South Carolina facility
            Organization                    –   SAP
            Omnium Plastic                  –   eFORS – sequence demand solution,
            • Standardized                      standardized solution worldwide.
              configuration for all      Key steps:
              PO facilities.                –   Understanding the change
            • Modules MM,PP ,               –   Impact analysis
              MD, SD, FICO                  –   Configuration , master data development
                                            –   Conference room pilot
                                            –   Training execution
                                            –   Launch
                                            –   Sustain deployment




3/18/2010                             Dean Maple                                          40
Plant Management- Norcross,Ga.                              Plastic
                                                                Omnium

     • Sequence assembly and delivery operation to supply GM Doraville
       GM201 mini-van. 90,000vpy
     • Injection molding 2,300 ton for the injection of GM and BMW
       components
     • Diverse workforce multilingual work force
     • Original temporary assignment was 6 months to prepare to
       shutdown the facility with planned Doraville shutdown.
       Assignment changed to sustain operations with extension of GM
       operations through September 2008.
     • Prepare plant for reinvestment to sustain operations with a new
       business model.




3/18/2010                         Dean Maple                             41
Plant Management- Accomplishments

     • Received TS16949 Certification – One of two plants in the division
       of 30 operations worldwide to certify with zero findings.
     • Twelve month delivered PPM to GM Doraville of < 40
     • Zero lost time injuries
     • Zero recordable injuries
     • 100 % sequenced on time delivery performance to GM Doraville
       for 90,000 vehicles
     • Favorable 12 month budget performance
     • Implemented key process and cost savings actions resulting in
       $ 200K favorable contribution to operating budget.




3/18/2010                         Dean Maple                            42
Plant Management- Accomplishments

     • TS16949 Certification
            Recommendation




3/18/2010                      Dean Maple   43
Plant Management-TS16949 Certification
                      Auditor Comments

     Define strategy and objectives:
     +      Even with the facility being originally scheduled to
     be closed this year, the organization did very well in the
     achievement of established goals
     + Internal communications
     Develop people:
     + Development of bilingual for hourly employees Spanish to
     English, and for management English to Spanish.
     + Associate audit preparations – visual audit tips / hint
     placards
     •Develop product/process:
     -         No current activities
3/18/2010                         Dean Maple                       44
Plant Management-Industrial Indicators




3/18/2010              Dean Maple             45

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Career Accomplishments 3 18 2010

  • 1. Dean Maple - LSSBB Career Accomplishment Summary Dean Maple 102 Aiken Farm Road Pickens, South Carolina 29671 864-878-1799 demap102@charter.net 3/18/2010 Dean Maple 1
  • 2. Index  Summary of Qualifications  Key Accomplishments & Supporting Data – Materials/Prod. Control – Manufacturing – Supply Chain – Project Management – Systems Implementation – Problem Solving – Plant Management  Certifications  Performance Reviews & References 3/18/2010 Dean Maple 2
  • 3. Career Summary  Extensive experience assessing operations, improving performance and reducing costs.  Proven experience in Supply Chain Management and Execution and Lean Manufacturing resulting in savings in excess of $1.5 million dollars.  Key implementation experience with SAP and Manufacturing Execution Systems implementation.  Committed to quality with certification experience in ISO 9000, QS 9000 and SPC. 3/18/2010 Dean Maple 3
  • 4. Certifications – Lean Six Sigma Black Belt 3/18/2010 Dean Maple 4
  • 5. Letter of Reference  Borg Warner: Mr. Dave Baker Human Resource Manager. Phone 864-985-5141 3/18/2010 Dean Maple 5
  • 6. Letter of Reference - Mr. Wayne Smith Former VP Manufacturing for Ryobi, Current Exec. VP Rival- Holmes Group T h e H o lm es G ro u p O n e H o lm es W a y M ilfo rd , M A 01 7 5 7 D e ce m b e r 2 0 , 2 0 01 T o W ho m T his M a y Co n ce rn : P le a se a cce p t th is d o cu m e n t a s a re fe re n ce fo r M r. D e a n M a p le. I w o uld re co m m e n d th a t a n y o n e in th e a re a s o f b u sin e ss, m a n u fa ctu rin g , o r e d u ca tio n u tilize M r. M a ple 's ex te n siv e k n o w le d g e a n d e x p e rie n ce . H e is a sk ille d , m a n a g e r, co m m u n ica to r, a n d le a d e r, p a rticu la rly in th e fie ld s o f o p e ra tio ns, b u sin e ss, a n d su p p ly ch ain . I h a v e k n o w n M r. M a ple fo r n e a rly te n y e a rs. In th e 9 0 's h e w o rk e d fo r m e a s a n e x e cu tiv e h e a d in g a v a rie ty o f a re a s fro m o p e ra tio n s to m a te rials to su p p ly ch ain . In m a n y ca se s h e a cte d a s m y "b a ck u p " a n d th e m a n a g e r I m o st d e p e n d e d u p o n . His im p le m e n ta tio n o f n e w a n d "u p to d a te " p ro g ra m s a n d te ch n iq u e s sa v e d th e co m p a n y tho u sa n d s o f d olla rs. H e is a d e p t a t co m m u n ica tin g a n d p re se n tin g o n th e fa cto ry flo o r, in th e cla ssroo m , o r in th e b o a rd roo m . H e is a h a rd w o rke r, a p e o ple p e rso n , a n d h is eth ics a re u n q u e stio n a b le. P le a se fe el fre e to co n ta ct m e to discu ss a n y d e ta ils o f th is re co m m e n d a tio n . S in ce re ly , W a y n e F . S m ith Phone: 660-885-5564 (X168) Cell: 816-804-6739 E m ail: w fsmith@ theholm esgroup.com 3/18/2010 Dean Maple 6
  • 7. Performance Evaluation - Carl Klebe VP Operations Ryobi Review conducted on move from Manufacturing to Material responsibilities. ( 1996 - 1997) More important to the decision to place Dean in the Materials function are the following aspects of his performance during the two years prior to the decision. First he consistently demonstrated the ability to deal with change and new situations. Second, he was consistently willing to take responsibility for and leadership of all assignments. He demonstrated both experience and a solid understanding of Production Control and Materials Management He is willing to take personal risks to accomplish changes needed to move the plant operations forward. He is willing and does put in the extra effort required by challenging and critical assignments 3/18/2010 Dean Maple 7
  • 8. Materials/Prod. Control Initiatives  Assembly line uptime initiative  MRO - Integrated Supply Implementation  Vendor Managed Inventory Implementation  Kanban/Lean Manufacturing Implementation  Pricing and Source Negotiations  Logistics initiatives 3/18/2010 Dean Maple 8
  • 9. Materials/Prod. Control Initiatives Assembly Line Up Time Hours  Situation: Significant assembly line interruptions for 35 late delivery, or misplaced 30 inventory. 25  Actions: Analyze root cause, 20 utilize fishbone analysis and 15 implement Kaizen team. 10  Results: Significant reduction 5 in assembly line downtime. 0 Jan-97 Sep-96 Nov-96 May-97 Mar-97 Percent Year 1996 1997 Change Inventory Accuracy 104.8 77.5 -26.05 Inventory Downtime hour results comparison Delivery & 1996 vs 1997. DT Hours costed at Availability 246.9 88.7 -64.07 $400/hr savings of $72,400 3/18/2010 Dean Maple 9
  • 10. Materials/Prod. Control Initiatives Ryobi MRO - Integrated Supply Situation & Tasks  1/7/97 Current Inventory $ 1.3 million ( not including maintenance)  1996 Inventory Turns = 1  1996 # of vendors = 700 (Includes capital equip.& contractors )  1996 Purchases = $ 4.8 million(less capital equip.& Const.)  Over $400,000 of current inventory has had no activity since December 1994.  Stockouts still shutdown operations waiting on vendors to supply from blanket orders.  1996 cut over 10,000 Purchase Orders & Processed 8,875 Invoices 3/18/2010 Dean Maple 10
  • 11. Materials/Prod. Control Initiatives Vision MRO - Integrated Supply Statement  To eliminate the MRO products inventory, daily purchasing and inventory management function of this inventory for our plant, focusing on the following key benefits:  Improved cash flow.  Reduced cost of products purchased.  Reduced inventory carrying costs.  Improved focus on core business.  Reduced purchase transaction costs. 3/18/2010 Dean Maple 11
  • 12. Materials/Prod. Control Initiatives Decision MRO - Integrated Supply Agreement Implemented  Proposal Summary – Use up active inventory. – Guaranteed savings 4% hard cost in first year. – Projected annual savings breakdown.( D.M.)  1st Year $ 376,610  2nd Year $ 298,610  3rd Year $ 233,810 – Actively drive down Ryobi Owned Inventory – Implementation throughout facility in 1997. – Key to all this is a Partnership Relationship 3/18/2010 Dean Maple 12
  • 13. Results Materials/Prod. Control InitiativesSince Integrated SupplyTarget Start Inventory Trend Date Reduced MRO - Integrated Supply by $561,224 in Acct 1607 Eliminated 1605 $ 65,000 Total reduction project to date is $626,224 Inventory reductions continued through 1999. With cost savings meeting agreed objectives. 1607 MRO Inventory Account Stock Status ( Weekly Inventory) $1,400,000 $1,200,000 $1,000,000 $800,000 $600,000 $400,000 $200,000 $0 Beg. 15- 29- 10- 21- 2- 13- 25- 6- 17- 28- 11- 23- 4- 15- 27- 8- 21- Feb Mar May Jun Aug Sep Oct Dec Jan- Feb- Apr- May- Jul- Aug- Sep- Nov- Dec- 98 98 98 98 98 98 98 98 98 3/18/2010 Dean Maple 13
  • 14. Materials Initiatives V M I - Fasteners  Situation: Delivery Issues, High Inventory, Escalating Pricing, Product Quality  Actions: Single source supply, on site inventory ownership, Kanban delivery to line side, elimination of returns to stock.  Results: Elimination of company owned inventory $ 100,000 reduction, elimination of delivery problems, purchase upon consumption of product.Implementation of Kanban pull.Reduction in headcount 2 employees.Elimination of returns to stock. 3/18/2010 Dean Maple 14
  • 15. Focused Efforts on reduction of Materials Initiatives stock transactions and improved use V M I - Fasteners of Kanban point of use replenishment stocks. % of Total Pcs Returned to Stock Each Week 35.00% 30.00% 25.00% Percent 20.00% 15.00% 10.00% 5.00% 0.00% 7- 11- 15- 22- 26- 31- 5- 9- 13- 18- 22- 27- 31- 7- 11- Dec- Jan- Feb- Mar- Apr- May- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Mar- Apr- 97 98 98 98 98 98 98 98 98 98 98 98 99 99 99 Week Percent Log. (Percent) 3/18/2010 Dean Maple 15
  • 16. Materials Initiatives: Kanban  Plastic Omnium: Implemented Internal Kanban pull between stocks warehouse. Improved inventory accuracy from an average 25%monthly error ($400,000) to an average of 2.5%.  Borg Warner: Expanded the external demand pull Kanban system to include Hyundai. Implemented computerized Access database system for managing Kanban communication to suppliers.  Ryobi: Implemented external demand pull Kanban through the following areas: Plastics, Fluids, Packaging, Fasteners, and Motor materials. Resulting in a reduction of Raw & Wip inventories of $2 million dollars. 3/18/2010 Dean Maple 16
  • 17. Materials Initiatives Price & Source Negotiations  Annual Contract Negotiation: – Flat rolled steel purchases * $ 1.6 million dollars contract for stamping materials. Established product family group pricing and a vendor owned finished inventory daily shipping bank. – Aluminum Die Cast ingot purchase contracts negotiated based upon futures metal market projections, annual purchases in excess of $5 million dollars. Realized a $170,000 annual savings. 3/18/2010 Dean Maple 17
  • 18. Materials Initiatives: Logistics  Plastic Omnium: Implemented a materials/logistics system, SAP 4.6, major improvement to customer suppliers rating for logistics functions.  Borg Warner: Implemented cost savings on transportation with the use of Milk Runs, single source transit & customs clearance of $ 250,000.  AFCO: Expanded Milk Run, returnable container programs to expand company program for elimination of waste and refuse disposal at the plant. Estimated annual savings were $ 100,000.  Ryobi: As a component of my procurement responsibilities I studied routing of Far East purchases. Finding that 85% of all purchases came via the most expensive routing the routing was changed and pricing negotiated with ocean carriers resulting in a $250,000 savings. 3/18/2010 Dean Maple 18
  • 19. Plastic Logistics – Inventory Mgt. Omnium  First Objective: Make it accurate. – Establish Control – Train the employees – Cycle count – Focus on corporate objective of <3% error in inventory. 3/18/2010 Dean Maple 19
  • 20. Plastic Logistics – Inventory Mgt. Omnium Duncan Month End Inventory Results  Second Objective: Find $3,000,000 ways to reduce $2,500,000 $2,000,000 it. $1,500,000 – Procurement/ $1,000,000 Planning Management $500,000 $0 – Supply Chain Management De -0 4 v Fe -0 4 Ju 0 4 Ap - 04 Ma - 04 n n Au l Au l-04 Se - 04 Oc - 04 4 Ma 4 Ja e c J u -04 Se g Ma r r pt b No - 04 t y Ju Ap Ma Oc No Ja Ju r- 0 c-0 Fe Transportation n- – D v n r b g p y t Management Total Inventory 2 per. Mov. Avg. (Total Inventory) 3/18/2010 Dean Maple 20
  • 21. Logistics – BMW Supplier Rating Best Result for Plastic Omnium Logistics Score since the beginning of the relationship with BMW, 10 years. 3/18/2010 Dean Maple 21
  • 22. Manufacturing - Initiatives ( Ryobi)  Productivity - Die Cast Machining  Kaizen Continuous Process Improvement  New Product Introduction  Motor Assembly Line Project 3/18/2010 Dean Maple 22
  • 23. Manufacturing Initiatives- Die Cast Machining Productivity Reduced Scrap, Reduced Overtime Hours Support Productivity 12 % improvement in productivity acknowledged by the VP of Operations Focus on productivity = Reduced Secondary Labor, 3/18/2010 Dean Maple 23 Reduced Indirect & Increased Direct Labor Efficiency
  • 24. Manufacturing Initiative - Die Cast Machining Productivity  Results:  Situation: Low  Zero defects for nine Productivity, High Scrap, continuous months(through High Indirect and project completion) with Secondary Labor major customer. Expenses.  $ 100,000 Savings on cell  Actions: Form Kaizen reorganization. Team, Capacity Analysis -  Employees from Shop floor Study Constraints, part of Kaizen team for Implement SPC, Educate continuos improvement. & Involve Employees  Sustained 10-12 % productivity improvement. 3/18/2010 Dean Maple 24
  • 25. Manufacturing Initiative - Die Cast Machining Cellular production startup of a major product Productivity introduction. Constrained by process and launch New product startup to market timing requirement. Leap Router Parts Machined 15,000 Production 10,000 5,000 0 2-Oct 9-Oct 16-Oct 23-Oct Weeks Total Machined Log. (Total Machined) Leap Router Parts/Hour 100 Production 50 0 2-Oct 9-Oct 16-Oct 23-Oct Weeks Parts per hr Log. (Parts per hr) 3/18/2010 Dean Maple 25
  • 26. Manufacturing Productivity Initiative - Assembly (see project mgt..)  Letter of recognition for project leadership from startup, full production release, Kaizen training of employees and order fulfillment to customer. 3/18/2010 Dean Maple 26
  • 27. Project Management - Manufacturing and Materials Initiatives A re a D e s c rip tio n S itu a tio n C o m m e n ts M a te ria ls : Vendor P e rfo rm a s a n C o m p a n y in C o m p a n y: M anagem ent & o n s ite je o p a rd y o f A s s o c ia te d Q u a lific a tio n m a te ria ls a n d s h u td o w n o f Fuel Pum p m a n u fa c tu rin g T o yo ta a n d C o rp o ra tio n s u p p o rt fo r H onda D a te : 9 /2 0 0 0 s u p p lie r A s s e m b ly L in e s O p e ra tio n s / P ro je c t C a s h Excess S e rio u s P ro c u re m e n t R e d u c tio n o f In ve n to ry o f fin a n c ia l C o rp o ra te in ve n to rie s . M fg . & c o n d itio n In itia tiv e R yo b i G e n e ra te c a s h P u rc h a s e d o b je c tive to D a te : 2 /2 0 0 0 flo w fro m F in is h e d G o o d s e lim in a te $ 2 5 e x c e s s in v. m illio n d o lla rs e x c e s s in v. 3/18/2010 Dean Maple 27
  • 28. Project Management - Manufacturing and Materials Initiatives Area D e s c r ip tio n S itu a tio n C o m m e n ts S ta m p in g L e a d C ro s s T h e s ta m p in g D ir e c te d to O p e r a tio n s fu n c tio n a l o p e r a tio n n e g o tia te a n d O u ts o u r c e te a m to w e re n o r e lo c a te th e R yobi o u ts o u r c e th e lo n g e r b u s in e s s to a n D a te :1 /1 9 9 9 s ta m p in g c o n s id e r e d a o u ts id e o p e r a tio n c o re ve n d o r. c o m p e te n c y B udget $ 1 5 0 ,0 0 0 In s o u r c e L e a d a cro s s M a n u f a c tu r in g R e n o v a te M o to r M o d u le fu n c tio n a l c o n tr a c t to space, 2- p r o d u c tio n te a m to lo c a te s u p p ly m o to r s m o n th R y o b i D a te : m o to r fo r f lo o r c a r e tim e ta b le 7 /1 9 9 9 p r o d u c tio n to c u s to m e r f o r p u r c h a s e a ll th e fo rm e r th r e e y e a r s e q u ip m e n t, s ta m p in g a r e a tr a in e m p lo y e e s . B udget $ 1 5 0 ,0 0 0 3/18/2010 Dean Maple 28
  • 29. Project Management - AFCO on site vendor support  Situation: Supplier selected was not able to adequately support component demand upon release to produce, jeopardizing vehicle assembly schedules at Honda, Toyota and Numi. I was selected to perform as the on site vendor support person in Detroit.  Actions: Implemented Master Schedule, Subcontractor schedules, evaluated, recommended & pushed implementation of shop floor materials control and equipment layout changes. Daily productivity reporting. Visual schedule and production posting.  Results:Supplier shipments on time, quality problems addressed and vehicle assembly line downtime avoided. 3/18/2010 Dean Maple 29
  • 30. Project Management: Ryobi Project Cash - Finished Goods Team Leader  Situation: The company was severely effected by the Asian banking crisis and a the difficulties of managing supply chain purchases for Far East finished goods purchase decisions. Finished Goods inventories were at an all time high of $80 million dollars and in a cash supply crisis. An S & OP process was not in place nor a procurement organization separate from the sales & marketing organization.  Actions: A cross functional team was formed along with a Consulting team from Delloite & Touche. Analysis of forecasting, buying practices, implementation of a master procurement schedule and creation of a the Demand Planning discipline to lead the S & OP process and create a separate procurement department was implemented. 3/18/2010 Dean Maple 30
  • 31. Project Management: Ryobi Project Cash Finished Goods Team - Results A $ 30 Million dollar reduction in inventory was realized and enough cash generated to significantly reduce borrowing requirements.  S & OP process was implemented providing discipline to coordinate the key functions of : C – New Product Planning C U U S – Demand Planning S Integrated T T O – Supply Planning Business O M Plans M E – Financial Planning E R R 3/18/2010 Dean Maple 31
  • 32. Project Management: Stamping Outsource & Motor Insource Project Leader - Project Description  Stamping - Outsource the approximately 300 components manufactured in house to an outside supplier with the key criteria to complete the project in six months with no interruptions in manufacturing assembly schedules and utilize the existing work force through the end of the project to support building inventory banks to support the move.  Motor Manufacturing- Continuing after completion of the stamping project, renovate the manufacturing area, install equipment, train new employees and deliver product to the customer in less than 3 months from start of project. 3/18/2010 Dean Maple 32
  • 33. Project Management: Stamping Outsource & Motor Insource Project Leader  Key Project Functions Addressed: – Human Resources – Engineering – Supplier Negotiations – Maintenance – Logistics – Planning – Equipment Sales and Relocation 3/18/2010 Dean Maple 33
  • 34. Project Management: Stamping Outsource & Motor Insource Project Leader Timeline Jan-97 Feb-97 Mar-97 Apr-97 May-97 Jun-97 Jul-97 Aug-97 Sep-97 Oct-97 Stamping Supplier Negotiations Project Release - Stamping Component Transf er Plan Executed Equipment Transf erred Stamping area renovation Motor Component Supplier Negotiations Eng, &Equip Req. Executed & Installed Employees Trained & Production Startup 3/18/2010 Dean Maple 34
  • 35. Project Management: Stamping Outsource & Motor Insource - Project Results  Projects on Time :  No Interruptions in Manufacturing Assembly - Stamping Project:  Projects within Budget:  Stamping $150,000Budget - Came in under budget and generated over $500,000 in income from the sale of the equipment.  Motor Project $150,000 Budget - Came in under budget  Employees:  Stamping - Excellent cooperation all provided jobs who wished to work, 3 senior employees retired.  Motor Project: All trained, staffed on schedule and beat previous production rates & quality standards. 3/18/2010 Dean Maple 35
  • 36. Automotive Launch Project – BMW E53 Mu Facelift – Successful “Digital Launch” at BMW E53 Face Lift Timing Plan Planned Finish Date Area: Logistics - Dean Maple Important elements not fulfilled - danger of missing due date Revision Date/CW: May 23 2003 - CW 21 Some elements not fulfilled; counter measure needed to regain planned timing Revision Level: A According to plan Months 2003 January February March April May June July August September October Calendar Week 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Verification of PTO Releases (TOD) 100% Complet e Verification of PS1 Releases 0% 100% Verification of PS2 Releases 0% 50% 100% Verification of AS Releases 0% Deliver PTO/KEX Parts 10% 15% 20% 40% 50% 60% 70% 80% 90% no issues Deliver PS1 Parts 0% 20% 60% 70% 100% Deliver PS2 Parts 20% 30% 40% 50% Deliver AS Parts 0% Elimination of EDI Errors 0% 20% 20% 20% 30% 40% 50% 50% 50% 50% 60% 60% 60% 70% 70% 70% 70% 70% 70% 100% complet e - no er r or s Validation of Shipping Rack Allotment 0% 0% 10% Waiting to determine pro to feasability fo r density Run-out Plan 0% 10% 20% 20% 20% 30% 30% 30% Initial run o ut plan needs to be drafted and appro ved - P riscilla/A nn Production Inventory Runout Management 0% Current E53 Front Service Validate layout/location w/Process Team 0% Run-out Plan (one time buys, etc.) 0% Management of new service line PTO/KEX 52 PVS1 64 PVS2 43 ANLAUF 134 SOP 400 Vehicles per day 3/18/2010 Dean Maple 36
  • 37. Systems Implementation  SAP 4.6 – Plastic Omnium: Monthly Inventory Adjustment % of Ending Inventory SAP had been installed for 5 years but never properly used 35.0% 32.9% for procurement, inventory 30.0% 25.9% management and execution. 25.0% 21.5% Implemented 4.6 in March 2003. Key functions and 20.0% % responsibilities executed for a 15.0% 9.9% successful implementation. 10.0% 6.5% 6.5% Immediate results achieved 5.02% 5.0% with inventory accuracy. 0.0% Jan Feb Mar Apr May Jun Jul Month 3/18/2010 Dean Maple 37
  • 38. Computer Systems Implementation  SAP 4.6 – Plastic Omnium: Procurement, Inventory Control, Transaction Control – Material Movement, Production Reporting, Customer Delfor Management, EDI  SAP 4.0 Ryobi: Warehouse Management, Master Production Planning, Master Procurement Planning, Material Movement, Sales Forecasting, Sales & Operations Planning Production Reporting.  Synquest Material Execution System – Ryobi – Shop floor control for work center loading and detail planning. Complement to SAP.  Early career projects include: Order entry, shop floor control 3/18/2010 Dean Maple 38
  • 39. Systems Implementation Plastic Omnium SAP Version 4.6  Planning Execution  Stock Coverage Analysis  EDI Requirements Communication  ASN Communication  BMW SPAB Interface  BMW Technical Order Data Management 3/18/2010 Dean Maple 39
  • 40. Systems Implementation Plastic 2005 SAP Upgrade Omnium SCOOP Project  Led the project initiative for implementation of BMW related functions • Supply Chain for the Duncan, South Carolina facility Organization – SAP Omnium Plastic – eFORS – sequence demand solution, • Standardized standardized solution worldwide. configuration for all  Key steps: PO facilities. – Understanding the change • Modules MM,PP , – Impact analysis MD, SD, FICO – Configuration , master data development – Conference room pilot – Training execution – Launch – Sustain deployment 3/18/2010 Dean Maple 40
  • 41. Plant Management- Norcross,Ga. Plastic Omnium • Sequence assembly and delivery operation to supply GM Doraville GM201 mini-van. 90,000vpy • Injection molding 2,300 ton for the injection of GM and BMW components • Diverse workforce multilingual work force • Original temporary assignment was 6 months to prepare to shutdown the facility with planned Doraville shutdown. Assignment changed to sustain operations with extension of GM operations through September 2008. • Prepare plant for reinvestment to sustain operations with a new business model. 3/18/2010 Dean Maple 41
  • 42. Plant Management- Accomplishments • Received TS16949 Certification – One of two plants in the division of 30 operations worldwide to certify with zero findings. • Twelve month delivered PPM to GM Doraville of < 40 • Zero lost time injuries • Zero recordable injuries • 100 % sequenced on time delivery performance to GM Doraville for 90,000 vehicles • Favorable 12 month budget performance • Implemented key process and cost savings actions resulting in $ 200K favorable contribution to operating budget. 3/18/2010 Dean Maple 42
  • 43. Plant Management- Accomplishments • TS16949 Certification Recommendation 3/18/2010 Dean Maple 43
  • 44. Plant Management-TS16949 Certification Auditor Comments Define strategy and objectives: + Even with the facility being originally scheduled to be closed this year, the organization did very well in the achievement of established goals + Internal communications Develop people: + Development of bilingual for hourly employees Spanish to English, and for management English to Spanish. + Associate audit preparations – visual audit tips / hint placards •Develop product/process: - No current activities 3/18/2010 Dean Maple 44