Dave Duncan

David Duncan is an Associate of TranSystems | The ACCESS Group and has 25 years of experience in engineering, operational and leadership positions. Dave’s automotive experience is with OEM’s, Tier 1 and Tier 2 Suppliers. He has worked in Product Engineering, Process/Manufacturing Engineering, SQA and Program Management. Dave has managed many individual projects, new model programs, and entire manufacturing plants. Companies that Dave has worked with include Ford, Nissan, Midwest Stamping, Stamped Products and SW Manufacturing.

Dave was instrumental in Nissan’s initial U.S. sourcing programs and helped develop their part approval process. He was instrumental in adding ‘part functional requirements’ as part of the SIR (PPAP) process. He also initiated the sourcing of stamped parts with Calsonic Yoruzo, Yamakawa (now Unipress), and Cosma. Dave conducted Quality System Surveys at Nissan suppliers and trained Nissan engineers to conduct surveys. Dave excelled in the area of Supplier Development. His work with PK USA enabled them to improve their Quality rating from 65% (unsatisfactory) to over 90% (outstanding). Dave was the Bodyside engineering team leader for the initial Altima Program and also handled the 1991 Sentra Design. He led Nissan Designers and on-site supplier engineers in this, the only original design project at the Smyrna location. At Midwest Stamping, Dave was in-charge of the Villager/Quest Program. He managed the cross-functional teams, which involved 3 Midwest plants. Dave insured all PPAP’s were submitted as scheduled and was the company’s representative at the Ohio Assembly Plant during launch. Dave was the main customer interface, which involved both Ford and Nissan (joint venture program). Dave was instrumental in Midwest to achieving QS 9000. He was an active member of the QS 9000 committee and performed internal audits at the Plant. At Stamped Products, Dave re-structured the Tooling Department for improved die maintenance and tracking. This resulted in a reduction of dies “out for repair” by 45% and allowed better production scheduling. Dave also implemented an improved steel sourcing strategy, which resulted in $6,000 monthly savings. This also reduced scrap cost by 20% due to clarification of steel specs and supplier accountability. Dave implemented systems and procedures, which enabled Stamped Products to achieve QS 9000. Dave’s work and ability was recognized and he was promoted to manage the Plant Operation after 9 months with Stamped Products. This allowed Dave to implement cross-functional improvement/ Kaizen teams.

At SW Manufacturing, Dave was in-charge of all New Model Programs. He led a cross-functional team of SW Associates during Japan trials. Dave and his engineering team reduced capital spending by 15%. This was achieved by working closer with tooling and equipment suppliers to reduce cost and develop improved tooling. Dave also required suppliers to participate in trial events before buy-off. Dave gained the trust of all employees, which enabled him to get full support to attack equipment and production problems. The resolution of these problems helped defeat and avoid a union campaign.

Dave interacts well with all people from all levels. His work at Ford and Nissan helped his performance with the automotive supplier companies. Dave has traveled to Japan seven times, participating in trials and meetings. He’s been to customer facilities in Mexico to solve problems. Dave is considered a ‘team player’ and gets involved with all departments, suppliers and customers. He has managed up to 200 employees and all operational departments at a manufacturing facility, and at the same time has handled the detailed engineering, quality and project work.

David has a BS in Mechanical Engineering from Tennessee State University and an MBA from the University of Detroit. Some of his additional training is as follows:

• QS 9000 Auditor
• Toyota Production System
• Program Management
• Kaizen / Continuous Improvement / Lean Manufacturing
• Problem Solving Techniques, 8D process