When I decided to write a blog, I thought it was important for readers to understand my roots. The sum of my experiences made me into a common sense based and hands-on leader.
Business experience for me started early as a helper to my dad installing ceramic and slate tile. You began as a go-for, then progressed to mixing mud, grouting tile, and installing. He was an exceptional craftsman and a true taskmaster. He told my younger brothers and me that, “If we learned a trade, we would never go hungry.” Although we chose to do something different for a living, we did learn some good lessons from him:
1. No matter what, answer the bell in the morning.
2. If you’re a pro, you’ll take the field under any condition and make something good happen.
3. If you decide to do something, give it your best and do it well. Otherwise, move on…
Following this early experience in the trades, I spent 4 years in the Navy. I successfully completed the Navy’s 600lb. & 1,200lb Boiler Tech schools. Aboard ship, I jumped at the chance to move out of the fireroom to handle topside 3M, the Navy’s (PM) preventative maintenance program. I also ran refueling and material transfer rigs. I learned about how important PM is in a tough environment.
Following my time in the service, I worked in oil-fired plumbing and heating throughout Long Island, NY. I installed boilers and serviced systems from old, coal-conversion units to modern technology.
We then decided to move to Tulsa, OK with my wife’s job. Rather than continue to work in the trades, I decided to try working in manufacturing. I took a trainee position for mechanical design in ABB Switchgear. I discovered I liked manufacturing even more than the trades. My manufacturing journey then began in earnest… Along the way, I managed to go to night school and earn my BS degree.
I’ve spent most of my adult life in various US manufacturing plants. Apart from Human Resources & Finance, I’ve had the pleasure of working for 2-3 years in every role in a manufacturing business on my way up to senior management. My early manufacturing experience was split between 2 major corporations. For the last twenty years, I’ve managed as a CEO for Private Equity. Company sizes ranged from $2MM to $100MM in Revenue. Regardless of the size or location, I consistently found a poor practical understanding of ideas like 8020 and Lean.
My journey from the early days of JIT (Just-In-Time) and Synchronous Manufacturing to TPS (Toyota Production System) was initiated by Shingijutsu consultants via Pratt & Whitney Canada’s ACE (Achieving Competitive Excellence) program. Over a 2-year period, these skilled advisors guided me through several events in my own plants. These experiences forever changed my approach to manufacturing.
I have trained many teams and transformed many plants through facilitating Lean strategies. To list a few, my teams became well versed in:
• Kaizen events
• SMED – Setup/Changeover reduction
• 5S
• BPR – Business Process Reengineering
• DFMA – Design For Manufacturing & Assembly
• 6-Sigma projects
We also converted several Engineered-to-Order (ETO) products into high-velocity Configure-to-Order (CTO) products. These initiatives drove speed and efficiency throughout the process resulting in competitive advantages and growth.
My career has included industrial, automotive, and aerospace experience on both a domestic and international level. I have also experienced both high-mix and repetitive manufacturing environments. My teams applied Lean tactics successfully in all these settings.
After 25+ years deploying TPS, I am surprised by the number of small to medium sized companies who have never used 8020 or Lean tactics. Unfortunately, I have also heard about some horror stories related to poor use of these tactics.
I decided to start this blog to provide small to medium sized company leadership a common sense understanding of Lean strategies. Detailed instructions related to each tactic is readily available, so I will focus more on application. You don’t need to know the underlying technology and algorithms to use cruise control in your car… I’ll do my best to keep this in mind while writing this blog!