Innovation

  • 3 Patents plus dozens of other product & process designs
  • Expanded Manufacturing Equipment & Tooling Capabilities
    • Retrofits at 10% cost to obtain 95% of New Equipment on 40+ yr old equipment
    • Multiple Package Styles from Single Tooling for Battery Blister Paks (PDF 179KB)
    • Auto-Orient Terminals & Components during insertion in PCB's, Process SMT
    • Rapid-Change for stepwise plastic weld assembly of specialty filters
    • Developed Software to read OCLC database & produce Se-Lin (83KB) & PDF & other labels
    • Developed software to manage transmitter recovery and assure return to owner
  • Others too numerous to list here, using metals, plastics, wood & paper

Analysis

  • Process - Including Six Sigma & ANOVA
    • Modeling manual procedures to produce automated duplication & enhancement
    • Review of design paramenters to assure Design For Manufacture and Assembly
    • Interrelated timing and clearances for multiple package from single tooling
    • Process tolerances and life testing via design & PDF of experiments and spreadsheet automation
  • Product
    • Structure, materials and assembly tolerances to enhance cost & reliability
    • Reduce damage loss & corrugated cost for Battery Blister Paks
    • Real-Time data collect & determine survivability for transmitters as processed
    • MRP barcode & auto-ID pick system to eliminate pull errors, ship lowest cost
    • Developed machines to automatically interrupt-weld bearing cages without deflection
    • Developed retrofit systems to auto run & balance large drill/bore bearing cages
  • Others, using CAD, Excel, PC, Calculator & Presentation Graphics, etc.

Leadership

  • Seek Solutions
    • Elim logistics conflict with Duracell schedule vs plants vs suppliers
    • Change priorities real-time to accommodate changing realities
    • Leave all possibles on table, let them be eliminated by their own merits
    • Treat all with equal respect, pay attention to them, and mentor wherever possible
    • Help people solve THEIR problem as you solve yours makes implementation a snap (429KB) & PDF
  • Reduce Conflict & Motivate
    • Use Team Building and concensus in establishing realistic objectives
    • Measure only against those understood criteria, and leave OWN claims to resume
    • Never fear to make appropriate decisions, and plan for contingencies
  • Maintain focus on quality, cost, results and optimism; it's contageous

Cost Reduction

  • Process
    • Uniform solution for multi-year equipment simplified install & maintain: $20MM
    • SPC real-time immediately shows problems, saves rework & warrantee costs: $27MM
    • Auto-orient part design allows auto-feed without monitor, so co-process: $3MM
    • Recognize that small early cost add for versatility can add greatly to bottom line
    • Bulk 1st Class mail vs. 2nd day air Recall Program & automated process: $13MM
    • Teach links and technologies to speed information & processing: $20MM
  • Product
    • Pull Plug (259KB) & PDF eliminated 50% of total assy labor time, added marketability: $5MM
    • Made domestic produced window shade lower cost than landed Taiwan competitor
    • Design for Manufacture & Automation, tolerancing, reliability, etc.
  • Continuous cost review and technology utilization to cut costs

Re-Engineering

  • Process
    • Not just different; BETTER. Use file share via net to track progress, prompt action
    • Presentation via video-conf with computer link for PowerPoint (PDF 179KB) & Excel
    • Email, e-commerce and website for info exchange, speed, avoid phone charges
    • Replace manual document control with linked construct for multi-SKU children
    • Prepare billing, reports, ship papers, error-proof peel-out labels for TRW
    • Teach links and technologies to speed information & processing
  • Product
    • Pull Plug eliminated 50% of RO module labor time, added marketability
    • Reduce & substitute materials via structural form, stamping, molding & assembly
    • Design for Manufacture & Automation, tolerancing, reliability, etc.
  • Modeling and CAD motion reviews to assure achieving objectives

Quality

  • Process
    • Strong application of SPC, Cp & CpK analyses, prediction, Six Sigma principles
    • Document prep and control for ISO9000 & QS9000, PFMEA, Control Plans, etc.
    • Design for Manufacturability including tolerancing & capability analyses
    • Managing team in 24/7 test protocol for real-world survivability prediction
    • Built math models for analysis to predict transmitter durability in real-time
    • Error prevention via auto-ID technologies, sequential controls, peel-out labels, etc.
  • Product
    • Found consistent problem in EOL data, led to Transmitter Rework Project
    • Eliminated varience effects within multi-tools for stamping & forming, assures assembly
    • Made deformable plug (259KB) & PDF with seal/camlok ring to fit commercial PVC tube without trim
  • Modeling and review of objectives, as well as implications, from changes

Results

  • Projects Completed On-Time, In-Budget
    • Ford so impressed, awarded TRW Q1 status (Top Tier Supplier) during recall
    • Prototype then production packaging adaptive allowed multiple pak (55KB) & PDF types at low cost
    • Testing showed fatal problem in transmitters, high reliability in corrective action
    • Various market segments opened via product and cost enhancements & designs
    • Se-Lin (83KB) & PDF supplies require patented drag disks, so protect Gaylord market for 17 years
    • Multiple repeat projects for clients, confidence in my deliverables
  • Hands-On & Through Others
    • Testimonials and Thanks for helping from most hourly employees at clients
    • Team members willing to stretch and build personal skillsets, add to client benefit
    • Bases for future improvements to packages, products, etc. due to versatility
  • Client benefit never less than 100 times my compensation

Profit

  • Direct
    • Lower costs for rework, warrantee elimination, added capacity TRW: $40MM
    • Elim need for added machines, better utilization of capacity Duracell: $55MM (PDF 179KB)
    • Design completion for Carrier scroll compressor & plant startup sooner: $35MM
    • Data Entry error elimination and on-site pick at warehouses for GE: $20MM
    • Shipping cost elimination via RPS/UPS vs LTL GE:, Bulk Mail vs 2nd day air TRW: $15MM
  • Indirect
    • Duracell confidence to launch Ultra despite misgivings because I proved it
    • TRW confidence that revision vs redesign was adequate to fix transmitter problems
    • GE & Carrier (and all clients') confidence that materials needed would be there
  • Summary: Clients reap more benefits than they expect. Period.