9511 Prairie Edge Road

Wonder Lake, IL  60097

PH:  815-728-1710

FX:  815-728-1720

Email:  dmarsh@bcsbydm.com

Goal

To help my Clients capitalize market opportunities through world class manufacturing operations that produce the highest quality goods at the lowest cost, satisfying customer expectations while maximizing profit potential.

Experience

Lean Manufacturing Services

·         Six Sigma – DMAIC methodologies to produce cost reductions

·         5-S – cost-impact projections, organizational improvements, audit programs, and successful independent cost-impact verification

·         Kaizen – team events, process mapping, value-added analysis, kaizen planning, implementation, and validation; successes in dozens of plants, various industries

·         QMS/EMS – ISO 9001/14000, QS-9000, TS 16949, etc.; cost-effective system implementation and certification; improved performance, reduced customer complaints, improved quality and morale, cost reductions

·         Foot-Steps Analysis – accurately predicted an operator fatigue and morale weakness in an Assembly operation; left untreated, within four weeks condition resulted in internal and external quality rejections and cost overruns; directed implementation of proposed countermeasures; eliminated customer complaints; revised process flow eliminated one of six operators (~$108K savings on three shifts) and reduced tact time / increased capacity

·         Targeted Cost Reductions – Stamping plant was about to lose a part that was being resourced by the customer to a supplier in China for ~18% price reduction; analyzed and proposed ~15% cost reduction based on combined improvements from steel supplier and equipment utilization; part retained and ultimately landed four other, related parts that had been produced by the Chinese supplier

·         Preventive Maintenance – Coating plant was running two, 10-hour shifts to allow for maintenance during ‘scheduled’ down-time but had a significant, growing backlog and was consequently considering adding new line for more than $2.5M to increase capacity; proposed equipment improvements for less than $1M that, when implemented, resulted in increased MTBF and reduced MTTR, increasing capacity more than 30% while reducing overtime by scheduling three, 8.5-hour shifts on five days and performing necessary preventive maintenance on weekends; >70% reduction in unscheduled downtime

·         Supplier Management – Assembly plant, eliminated >90% receiving inspection cost; implemented quarantine and cost reclamation programs for all suspect supplied product; protected assembly and customer-supply lines from risky and problematic suppliers; improved operational performance, reduced customer complaints to < 30ppm, and appropriately reallocated costs to external sources

·         Cost Reductions – developed new material handling processes in Plastic Injection-Molding plant, $280K overall / annual cost reduction (i.e. ~18% cost reduction first year with full capital equipment absorption); $350,000 overall / annual cost reduction in assembly plant by eliminating non-value-added paint / containment process

·         Staff Development - managed 70+ professional consultants nation wide in one firm

        established performance review processes in multiple plants:  annual, quarterly, monthly, ad hoc; implemented team-building activities:  charting, communications meetings, staff  training and development activities, competitions, profit-sharing

        directed removal of ineffective HR manager at Casting plant after multiple remedial efforts failed; new manager, demonstrating more innate talent for personnel evaluation and development strategies, was subsequently promoted to Corporate HR Director responsible for implementing lessons-learned and resulting performance improvements at over 15 plants across the organization

·         Business Management – directed development of key metrics and performance objectives at corporate, department, and management staff levels; facilitated and approved operational plan / strategy development for management teams and departments, including sales, manufacturing, purchasing, quality, and human resources

·         Program Development – drove implementation of APQP process in Machining plant that resulted in reduction of first-year – program ppm from over 20,000 to less than 100

·         Strategic Implementation – checked aggressive purchasing resourcing at one plant, pending new supplier performance validation; impact of start-up problems at new, offshore supplier were consequently limited and retained, local contingencies preserved customer-supply integrity; approved revised resourcing strategy the following year

·         Certified Auditor – lead auditor for ISO 9001 and QS-9000 registrations; audited more than 300 clients in North America and Asia over 10 years

·         Marketing Management – annual marketing plan / budget development; implementation of marketing plans; quarterly and annual performance reports; integrated sales / marketing strategies with corporate commercial products teams; distributor channel management; responsible for product line rationalization; reduced lead generation cost at Materials manufacturer from $28 to less than $1.00, each and increased sales from $5M in to over $11M over three year program