Success Stories
Plant Rebirth/ Revitalization/Profitability Improvement
Led the revitalization of an older office furniture manufacturing plant. Grew the plant from $22 million in annual revenue to $88 Million in three years with highly successful new product introductions and little increase in overhead and fixed costs. Took plant from a break-even situation to nearly 30% in net profit (as % of sales) in three years. Plant won the coveted Chairman’s Award for Quality from its $2 Billion parent company and was nominated for the Malcolm Baldrige award.
Restructuring/Foreclosure Avoidance
Led a major restructuring project for a metal fabrication company to save the company from imminent foreclosure by its lender. Reorganized staffing, implemented widespread cost reduction and productivity improvement projects. Implemented shop labor metrics and material utilization measurements. Led company from a negative $1 million monthly EBITDA to a positive $.5 Million EBITDA in eight months. Foreclosure by the lender was thwarted; company emerged from restructuring healthy and profitable without having filed Chapter 11.
Cost Improvement/ Inventory reduction
Led a major improvement project for a manufacturer of motorized recreational vehicles. Project encompassed all areas of the operation and resulted in major reductions ($3 Million) in WIP inventories, major reductions in raw material Inventories, and major reductions in operating costs (labor and materials). Developed internal metrics and scrap and rework accountability. Total one time savings were $4.2 million, recurring annual savings $2.3 million. Additionally, performed root cause analysis on hardwood cabinet handling and shipping damage, implemented corrective actions, and reduced rework by $268K annually.
Plant Startup
Led plant startup for a contract aerospace machining firm including purchasing all CNC machining equipment, building preparation, employee selection and training, all systems and procedures, and all business processes. Achieved certification from General Electric and Pratt and Whitney for machining turbine engine components made of inconel, waspalloy, hastalloy and titanium.