Innovative Solutions and Problem Solving Cases

I led a cross functional team at an idle critical supplier in Turkey for a U.S. based ballistics program.  The supplier had not produced hardware for over ten years.  In 6 months we partnered with the Supplier Team and restarted operations. We traveled to the site and recommended updates but also provided hands-on guidance and support sharing best practices and expertise. We enhanced communications with meetings and teleconferences to align technology best practices.  We provided top engineering, quality and technical mgmt support saving schedule and cost avoidance for the program restart in excess of ~$1.1B.

Our Team collects and analyzes data to identify opportunities to reduce cost growth, poor quality and late deliveries.  In one use case, this amounted to ~$34M in identified material costs and amounted to $10M in cost avoidance savings over 5 years.   We conducted several months of risk mgmt pre-work planning including meetings and teleconferences to align and exchange ideas based in industry best practices. We developed business imperatives including supplier improvement best-in-class engagements.

 As an Operations Subject Matter Expert, I planned and developed a new Integrated Manufacturing Teams formulated to work as Subject Matter Experts focused by commodity on special projects to drive velocity and acceleration. I mentored and trained other engineers and supply chain leaders in lean manufacturing and kaizen techniques. The Teams tackled $30M in cost avoidance opportunities globally.

 A Center of Excellence in manufacturing had a $1.5 M in annual waste facing the Operations Team. I launched an improvement council to investigate and identify issues across the site from Receiving Inspection to shipping. We engaged Logistics, Supply Chain, Product Assurance-Quality, and Engineering. We conducted material risk assessments and addressed the high pareto issues. We eliminated several of the high risk issues and increased quality saving over $2M through cost avoidance activities. The culture at the site was refocused to Innovation and best in class performance. 

HMMA was Hyundai's initial manufacturing activity in the U.S. and bolstered it's dominance in the industry.  In 3 years I supported the hiring and training of 2500 team members and brought a second shift production to full rate operations.  Several of my junior team leaders are now Sr. Leaders in the business.