TAG’s professionals are more than consultants, more than technical project managers, more than LEAN trainers and advisors. They are partners with the extraordinary expertise, skills, and tool sets required to help clients transform their operations into the flexible and efficient systems needed to thrive in today’s fiercely competitive world.
Our people are true believers, inspired by real experience in helping client companies transform to achieve desired outcomes. Through this transformation process, our clients become believers too.
Mike Brown is a managing principal with The ACCESS Group. Mike has had a dual background in both the manufacturing industry and the military. Mike has over 30 years experience in significant areas of growth and leadership during his career. He has held leadership positions in manufacturing, strategic planning, consulting, staffing, marketing and full management responsibilities of several businesses and corporations. Mike served as Director of Program Management for a major international aerospace manufacturer and has significant foreign and international trade experience. He has also managed numerous planning and industrial projects in the automotive, consumer goods, defense, boat, aircraft, and truck industries. Mike has in-depth experience in strategic and operational planning, ‘lean’ manufacturing analysis and implementation, and project leadership and manufacturing support services. Mike has worked and consulted with numerous divisions of Fortune 100 companies and has also developed successful programs and projects with small privately held firms. Mike is extremely adept in promoting and developing plans that help companies ‘change their business while they run their business’. Mike is a ‘change’ agent. He is critically aware of the tools available to develop a ‘lean’ enterprise and regularly works with companies who earnestly desire positive change and improvement. Mike has also had a significant military career lasting over 24 years. He served in numerous leadership and command positions while flying various fighter and transport type aircraft. Mike recently retired as unit commander of one of the largest flying units in the Air National Guard. Mike has a BS degree from the United States Air Force Academy, an MBA from Troy State University, and has completed numerous post-graduate courses and seminars.
close biographyCharles V. Hagood is a Managing Principal of The ACCESS Group and is President of TAG's affiliate company, Healthcare Performance Partners. Charles has held various executive and management positions in the Aerospace, Automotive, Consumer Goods and Manufacturing Consulting industries. He has also held a variety of positions including Program Manager of the Titan IV Rocket and V-22 Osprey Aircraft Programs with a Fortune 100 company, Senior Engineer, Consultant to numerous Consumer Goods and Automotive Related companies, Director of Resources, and Vice President of a Southeastern U.S. engineering firm.
Charles has overseen international and North American consulting assignments and projects for various Fortune 500 companies including lean enterprise/operational assessments, lean enterprise conversions, value stream analysis, inventory management programs, cost reduction programs, strategic planning, make/buy analysis, feasibility studies, due diligence support, competitive analysis, product benchmarking, operational analysis, and implementation planning projects. Charles has developed, led and facilitated kaizen events and manufacturing support teams for various companies, providing significant lead-time and cost reductions during both the development and full production phases of an operation. Charles has also led the planning and implementation efforts associated with Total Productive Maintenance (TPM) programs at various client companies as part of an overall lean initiative. In addition, he has planned and overseen plant relocations and process startups of various companies throughout the U.S. Charles’ manufacturing process expertise includes composites manufacturing, aircraft assembly and fabrication, appliance manufacturing, automotive assembly and components manufacturing, machining, energy systems component manufacturing, and service and support organization optimization.
Charles earned an AS degree in Mechanical Engineering Technology, an AE degree in Industrial Engineering, a BS degree in Operations Management, and an MBA degree from Belmont University. Charles is also a graduate of the University of Tennessee’s Lean Enterprise Systems Design Institute and TPM programs. He has participated in a number of workshops with Jim Womack of the Lean Institute. Charles is also pursuing his Masters of Reliability Engineering Degree from the University of Tennessee-Monash program.
close biographyKevin Saunders is Vice President of Client Services and Business Development with The ACCESS Group. Kevin has over 20 years of experience in management, marketing, and program development. He has held various management and leadership positions with two Fortune 100 corporations. Kevin initiated innovative programs for these companies and had responsibilities for program design, supplier negotiations, systems development, program management and customer relations. He introduced partnership programs that reduced system costs while achieving significant sales growth for both his client base and the suppliers. In his prior position, Kevin consulted with independent business owners to maximize productivity, reduce operational costs and increase sales. He has also held various management positions where he had responsibility for operations and facility management. Kevin has worked in many different capacities with client companies such as Nissan, Ford, Volvo, GE, Bosch, Tower, AO Smith, Dana, Olin Corp., Parker Hannifin, and American Greetings. Kevin has a BS degree in business from the University of Tennessee and has completed numerous courses in Lean principles and methodologies.
close biographyRonnie Daughtry is Manager of Project Operations and a Senior Lean Consultant with The ACCESS Group (TAG) with over seventeen years of experience holding various leadership and managerial roles in lean manufacturing, continuous improvement, supplier quality engineering, manufacturing operations, and human resources. The balance of his various leadership roles have been in the automotive sector for Robert Bosch Corporation in many locations in North America, South America, and Europe.
Ronnie has managed lean implementation efforts and applied lean principles in each of the roles he has held including the development and leadership of a division-wide strategy for lean manufacturing implementation as a base foundation toward lean enterprise. His approach is based on facilitating and driving value stream improvements with clients and colleagues worldwide. Ronnie has implemented and standardized site approaches to Single Minute Exchange of Dies (SMED) or Quick Changeover, Design for Manufacturability (DFM/DFA), Production System Design, Lean Line Design, Total Productive Maintenance (TPM), Manufacturing Analysis, and Mistake Proofing that have contributed to the overall lean system design in the locations where he has been associated. Ronnie has also implemented with great success an associate suggestion implementation system known as Kaizen Teian in many pilot sites. He is also well versed in Policy Deployment and Problem Solving methods.
In addition to being a lean practitioner, Ronnie is also a high energy speaker and a professional facilitator. Ronnie has been trained and certified as a Metaplan Facilitator and has moderated many leadership visioning and strategic planning sessions.
Ronnie has a Masters in Management and Organizational Development , Bachelors in Management and Human Relations from Trevecca Nazarene University, and an AS degree in Communications from Volunteer State Community College. Additional trainings are as follows: Steven Covey- Principle Centered Leadership Series, Seven Habits of Highly Effective People, Harris Lean Systems- Creating Continuous Flow and Making Materials Move, BAMA- Toyota Production System Executive Training, TPM Institute- Implementing TPM with Ed Hartman, and Lean Enterprise Institute (LEI) –Value Stream Mapping and Creating Continuous Flow with Mike Rother.
close biographyMr. Dan Ausbrooks is an associate of The ACCESS Group/TAG and has over twenty years experience in various manufacturing industries including diecast, machining, metal stamping, welding and final assembly. Dan has held positions as Quality Control Manager, Quality Supervisor, Quality Systems Engineer, Quality Engineer and Training, and Development Manager. Dan has worked with companies such as Federal Mogul, Frigidaire, Borg Warner and Tower Automotive. With the exception of Frigidaire, all experience has been with the automotive industry.
Dan has extensive knowledge in ISO9000/QS9000 and transition from QS9000 to TS16949 and is well versed in Quality Systems Development and Implementation. He is very knowledgeable in quality applications such as APQP, PFMEA, CP’s; 8-D/7-D Problem Solving Techniques, 5-Why’s, PPAP submissions, Gage Control and Calibration Programs. Dan is experienced with plant relocations, new plant ramp-ups, and has worked in both union and non-union environments. Dan possesses strong computer skills and is knowledgeable of numerous electronic document control programs such as Powerway and Impact. In addition, Dan has created and designed unique electronic documentation applications using MS Access and eliminated the need for multiple monthly license fees for packaged software.
Dan is a seasoned professional who portrays both hands-on and leadership characteristics. Dan has been a Certified Quality Engineer, Lead Auditor for ISO/QS9000 and is certified as an Internal Auditor for TS16949.
close biographyBob Bak is an Associate of The ACCESS Group (TAG) and has over twenty-five years of experience in manufacturing. He has devoted his career to productivity improvement using World Class Manufacturing techniques. Bob has focused in the areas of plant layout, cellular design, kanban and pull systems, 5S organization, and setup reduction. Bob has worked in many industries including aerospace, machining, metal fabrication, electro-mechanical assembly, appliance, packaging, metal stamping, metal spinning, and molding. Bob has worked with companies such as Genlyte, Thomas Industries, Giddens Industries, Ideal Industries, Rockwell Dodge, Remmele Manufacturing Company, Leonard’s Metal Incorporated, and Elkay.
Bob has led and contributed to many projects during his career. These include designing and implementing lean manufacturing principles, consolidating an aerospace machining company from three plants to one, and reducing a metal stamping and fabrication operation from two locations down to one. He has also relocated complete product lines from one division to another, and designed and implemented demand pull systems. Bob has designed layouts for several lighting companies, an HVAC manufacturer, three machining operations, two electro-mechanical assembly plants, and numerous precision metal fabrication companies. He also has facilitated many Kaizen events to accomplish process improvements.
Bob communicates well with people from the shop floor to the boardroom. He is a seasoned professional who demonstrates leadership with a hands-on style. He has been actively involved in all aspects of the principles of lean manufacturing. These include value stream mapping, cellular plant layouts, setup reduction, demand pull systems, kanban, point of use storage, cell design, single piece flow, 5S organization, employee lean training, standardize work, and other lean principles.
Bob has a BS degree in Mechanical Engineering from Chicago Technical College.
close biographySam Beaird has over 35 years of hands-on manufacturing management experience in a wide variety of products, processes, and environments. He has been a facilitator and consultant implementing the principles and techniques of the lean enterprise for the past four years. In industry he held senior management positions including general manager, vice president of manufacturing, plant manager, materials manager (including purchasing), and manufacturing systems manager. Sam has worked in a diversity of industries including mechanical power transmission products, large rotating machinery, electrical distribution equipment, electro-mechanical commercial products, automotive components, computers, and consumer goods. He has served such Fortune 500 companies as General Electric, Reliance Electric, and Dresser-Rand; small companies such as Lufkin Industries; and a European-owned company, S.E.W. – Eurodrive. He has consulted with clients primarily in consumer goods manufacturing.
Sam’s experience includes successfully planning and starting up new plants, orchestrating aggressive business turnarounds, and accelerating profitable market growth within existing organizations. His areas of expertise include developing and effectively implementing sound manufacturing strategies that address competitive and global issues; transforming businesses to operate according to the concepts and methodologies of the lean enterprise; designing or redesigning manufacturing operations and implementing training programs that enable companies to learn to be superior competitors; and applying advanced technologies to streamlining businesses and achieving best-in-class production performance. In addition, Sam has been at the forefront of creating nurturing organizational environments and developing high performance work teams that accelerate rapid improvements in quality, productivity, and cycle time. He has led successful strategic initiatives in sales & operations planning, lean manufacturing conversion, cycle time reduction, cellular manufacturing, focused factories, Total Quality Management, value stream management, large system changes, and high performance work systems. These initiatives have resulted in increased market value, performance, and profitability of businesses. Whatever the assignment, project, or responsibility, Sam brings a balance of technical acumen, manufacturing management expertise, and personal commitment to identifying opportunities for increasing market value and developing and implementing cost-effective solutions.
Sam has a B.E. in Mechanical Engineering (magna cum laude) from Vanderbilt University and an M.S. in Industrial Administration from Carnegie Mellon University. In addition, he is a graduate of General Electric’s two-year Manufacturing Management Program.
close biographyAndy Bolton is an Associate with The ACCESS Group and has over 21 years of experience in a business, materials management, and manufacturing environment. Andy is a successful leader with management experience in the aerospace, automotive, metals, and plastics industries. He is familiar with composites, injection molding, warehousing, distribution, business turnarounds and restructuring. Andy has held senior positions and led significant improvement projects involving materials and supply chain management, procurement, vendor relations, and MRP/ERP system implementations. He has facilitated and provided project leadership in several business start-up, turnaround, and restructuring operations. He has worked with retailers and distributors in developing, consolidating, relocating, and upgrading warehouse and distribution systems and facilities. Andy is very attuned to initiatives and operating systems designed to reduce inventory and improve customer service.
Andy has led and developed processes and procedures to support lean manufacturing initiatives that reduce critical path lead times, reduce expediting costs, and increase vendor involvement and relations. Andy has led projects that have reduced expediting costs by 53%, reduced the vendor base by 37%, and captured volume discount savings without compromising customer service. He has hands-on experience in vendor selection, purchasing, kanban implementation, and supply chain development. He has led improvement initiatives and in one case reduced a two million dollar shipment backlog in an organization by 80% in three months. Andy has evaluated and implemented successful software changes at company, division and corporate levels. He has led team/cell development to address key weaknesses in a procurement/supply-chain organization and, as a certified instructor, trained thousands of employees in both union and non-union environments.
Andy has a B.S. in Business Administration form the University of Arkansas and is a published author and presenter at APICS International Conventions. He has completed numerous industry specific training programs. Andy is an APICS Certified CPIM and a registered CPE instructor with the National Association of State Boards of Accountancy (NASBA).
close biographyGerald “Jerry” Bossolono is an associate of The ACCESS Group (TAG) and is a proven professional with over forty years of hands-on manufacturing management experience in the production and engineering disciplines. Gerald has held numerous positions within operational organizations from machine operator to shop floor management to the executive level. Gerald has worked in industries including: automotive, foundry, meat processing, appliance and injection molding equipment among others, in both consulting and full time positions. These experiences include working with multi-national and international conglomerate companies, such as, General Motors, Allis-Chalmers, Johnson Controls, Gateway Industries and others.
Gerald has led many projects throughout his career ranging from complex manufacturing systems design and implementation to lean manufacturing conversions of plant with operations in many different industries. His accomplishments include the consolidation project for an automotive seat belt manufacturer, which consolidated three plants into two plants, and increased production volumes and improved on time and complete shipments. Gerald developed and implemented a preventative maintenance program for an automated brass foundry that brought its downtime from 30% to less than 1%.
Gerald interacts well with people from all levels of the organization, which has been helpful in the success of the projects he has led. He is intimately familiar with JIT, Pull and Kanban systems, cellular and single piece flow manufacturing processes and utilizes Auto Cad to develop and implement plant layouts to accommodate these and other lean manufacturing principles. Gerald is an enthusiastic and highly motivated leader. Results are obtained by involving, teaching and working alongside the employees to ensure success during planning, implementation and after the engagement is completed.
Gerald’s certifications include SPC (Oakland University), Certification Mfg. Engineering (Allis-Chalmers), certified MTM Applicator (Allis-Chalmers), and Auto Cad (General Motors). He has also attended seminars in management, process control, production control, planning, MRP, industrial engineering, and business management.
close biographyRichard Bost possesses over 30 years of manufacturing experience. He has held a number of key positions including industrial engineer, manager of quality, senior manufacturing engineer and senior manufacturing consultant. His industry expertise ranges from consumer goods and automotive to metal forming and processing. He has worked with major companies such as AVCO Aerostructures, Precision Molding, United Technologies Corporation and Oster Corporation.
During Richard’s career, he has overseen the implementation of both ISO9000 and QS9000 certifications. Most recently his responsibilities included determining manufacturing processes, tooling, and part costing for a new product. In this capacity, he developed machine loads and capacities that maximized output and minimized cycle times. From a tooling perspective, Richard has written specifications, as well as instituted SPC programs for vendor tool qualifications. He has been responsible for plant layout, material handling, cellular manufacturing techniques, demand flow systems, and Kanban. Richard has had direct responsibility over the development of costing, setting time standards, and has totally implemented Activity Based Costing for an entire manufacturing company. In other project management roles, he has developed appropriations for capital expenses and followed the project through to installation. Richard is a seasoned professional with excellent project management, supervision and cognitive skills. His understanding and knowledge of budget preparation and management provide a valuable and integral key to total project management. Further, his grass roots understanding of discrete project elements allows him the opportunity to provides hands-on management of any project.
Richard has a Bachelor of Science degree in Industrial Technology from Tennessee Technological University. Also, he is certified in various time study methods including certification in MTM and as a MOST Systems Applicator.
close biographyMr. Rick Bradley is an Associate of The ACCESS Group with over twenty years experience in various vocations including the automotive, food, and clothing industries. Rick has held positions as Plant Engineer, Facilities/Maintenance & HSE Administrator, and Maintenance & Facilities Manager, as well as, having served in many project management roles. Rick has worked with companies such as Kraft, Oscar Meyer, Ford, Gary Company, Bendix, AlliedSignal, Bosch, and Visteon.
Rick began his career as a machinist and later furthered his education as an industrial electrician. His years of experience have allowed him to highly develop his skills that include machine controls, power distribution, pneumatic circuitry and plant layouts. He is well versed in PLC troubleshooting skills to include most brands of controls and actually teaches PLC ladder logic. Rick has developed complete Preventive Maintenance programs including researching and writing PM’s for entire facilities within the framework of QS9000. His QS9000 experience also includes achieving the level of lead auditor. Rick has been heavily involved in plant construction and start-ups. He has completed numerous facility related projects including developing specs for facility maintenance, implementing recycling programs, installation of chilled water systems, and facilities construction/renovations. Rick also proposed and installed an energy management system to improve HVAC usage that resulted in 30% savings. Rick has developed yearly capital projects to achieve process improvements and cost reductions. Rick has excellent interpersonal skills and is a seasoned professional who portrays both hands-on and leadership characteristics. Rick possesses strong CAD skills, including AutoCAD 14/2000 and he has a good working knowledge of MP2 Maintenance Management.
Rick’s formal studies in his technical trades began at the Ford Glass Plant where he took advantage of the Ford Apprenticeship Program as a Machine Repairman. He later attended the Tennessee Vocational Technical Center in Hartsville, Tennessee where he received his electrical and electronic training. He has also successfully completed many advanced training courses in the area of Maintenance Software, PLC’s, Microsoft Word, Microsoft Excel, and advanced training in AutoCAD.
close biographyKevin Brown is an Associate of the ACCESS Group with over fifteen years of experience in manufacturing and engineering. Kevin has worked in all phases of the product life-cycle, holding positions in product development and design, manufacturing systems design and implementation, project management, and engineering management. He is experienced in the automotive, appliance, consumer goods, and consulting industries, having worked with companies including Delphi Automotive Systems, A.O. Smith Water Products Company, Gibson Guitar Company, and Southern Pride.
Kevin has significant experience developing and implementing lean manufacturing systems, from individual assembly cells to entire plants. One of Kevin’s major accomplishments was leading manufacturing systems for the complete restructuring of a large fabrication and assembly plant. His responsibilities included implementing 5S, visual controls, pull systems, material flow strategies, and maintenance systems. This conversion reduced costs by approximately 30% and cut lead-times by 50%, while significantly improving flexibility to run new products.
Kevin has also applied lean strategies to the product development process. By working with corporate executives, sales/marketing, purchasing, and plant leadership, he was able to re-engineer the product implementation program. Within two years, the company was able to double the number of new products introduced, increase on-time delivery of new products, and cut lead-time for product introductions by 25%.
Kevin holds a Bachelor’s degree in Mechanical Engineering from the University of Missouri–Rolla. He also earned a Master’s degree in Manufacturing Systems Engineering from Lehigh University in Bethlehem, Pennsylvania. Kevin has completed a number of courses in lean manufacturing, including training with Akebono Brake Systems in Iwatsuki, Japan. He served on the Manufacturing Engineering Technology Industrial Advisory Board at Middle Tennessee State University for five years.
close biographyMike Cleveland has over 30 years experience in project management, startups, maintenance, facilities management, and quality. He is a proven leader, holding such notable positions as general manager, operations manager, division manager, quality manager, and chief engineer. He has completed numerous projects for key companies such as Owens Corning, Franke, International Trucks, H & M Architects/Engineers, Tennessee Valley Authority, CMC, Cygna, General Atomics, Florida Power, American Electric Power, Ford, Owens Corning, and General Electric.
Mike is a highly skilled professional who has researched, designed, developed, supervised, analyzed, evaluated and implemented enough projects, processes, and equipment to qualify him as an expert in a wide variety of fields. These include: process design improvements, process startups, quality improvement program development, facility assessments and planning, maintenance management, outage planning, contractor management, development of engineering control programs and contracts, procedure controls, corporate planning, negotiations, fuels, utilities, engineering, manufacturing, government industries, waste management, general operations, and safety programs. Mike has also evaluated the effectiveness and compliance of electrical/cable issues, fire protection, HVAC, conduit, and engineering programs. He has been responsible for initiating pressure test programs, predictive/preventive maintenance and thermography-based reliability centered maintenance programs. He has developed consulting programs for petro-chemical, manufacturing, fossil, nuclear and pulp and paper mills. Mike’s keen communication and other cognitive skills enable him to work well at all levels of the organization.
Mike possesses a MBA from Florida International University, and a BS Degree in Engineering Science from the University of Florida with a double minor in Electrical and Mechanical Engineering. Mike also received academic and hands-on training from the US Navy Electrical and Electronic School.
close biographyRandall Cole is an Associate of The ACCESS Group (TAG) and has over twenty-eight years of experience in manufacturing and materials management leadership roles. His operational experience includes extensive involvement in manufacturing operations, materials management, systems improvements and implementation, supplier development, customer relations, material handling, shop floor control, and supplier development activities. Randall has held numerous positions of increasing responsibility, including Manufacturing Manager, Director of Manufacturing, Procurement Manager, Materials Manager, Associate and Senior Associate Consultant. Randall has also served companies as a consultant in the positions of Customer Service Manager, Materials Manager, Director of Planning and Vice President of Purchasing. Randall has worked in several industries including automotive, component remanufacturing, assembly plant equipment, heavy truck, sporting goods, consumer goods, and appliance.
Randall has been responsible for implementing change throughout his career. He has led many projects ranging from systems data preparation and implementation, new product launches, and plant closings. He has led and been involved in computer systems improvements and installations, materials management and shop floor control development, and the implementation of scheduling processes and procedures. Some of his accomplishments include the development of bills of materials and all related database information for a start up company, new company supplier development, the liquidation of inventories, and the final build-out of significant product lines. He has worked with customers to determine anticipated needs, developed sales forecasts and Master Production Schedules, and worked with suppliers to insure needs are met while maintaining bankruptcy guidelines. Randall has developed significant material handling improvements including one foreign facility that reduced stocking travel distance by over 90%. He has also implemented improvements that eliminated triple handling of products, developed shop floor controls to eliminate operational bottlenecks, and regularly develops systems that eliminates past due customer orders. In one case, this resulted in the elimination of over $150,000 of premium freight charges annually. Randall also implemented scheduling improvements, shop floor controls and disciplines in shipping and receiving departments. Results yielding improvements such as an 88% reduction in shipping discrepancies, output increases of 35%, and an increase in sales dollars per overtime hour of 400% have been achieved.
Randall is a veteran of the United States Army. His educational background includes a Bachelor of Science Degree from Tennessee State University. Randall has received the Certified in Production and Inventory Management (CPIM) designation from the American Production and Inventory Control Society. He has attended numerous formal training courses in leadership and organizational development.
close biographyMr. Gary Cutrell is an Associate of The ACCESS Group with over 30 years experience, primarily working in the automotive industry. Gary has held positions as production supervisor, plant quality engineer, plant and division quality manager and quality consultant and trainer. Gary has worked with companies such as GenCorp, formerly General Tire and Rubber Company (Vehicle Sealing, Industrial Products and Tire Divisions), Haworth, Inc., Carrier, and Industrial Converting Company.
Gary possesses exceptional quality management expertise with good people skills and extensive experience in manufacturing, product design validation and international quality systems. He has specific experience in Supplier Development, Problem Solving Processes (8D), Statistical Methods and Process Control, QS9000/ISO9000 and Advanced Quality Planning. Gary's quality focus initiatives have included QS9000 certifications in two facilities, coordination of updating ISO Quality Systems and development of Supplier Quality Requirements manual and Corrective Action Request format for quality concern. Gary also served as a design team member, developed a Design Verification Plan (DVP) and managed testing to verify and validate design function. In addition, Gary has been heavily involved in problem solving and cost reduction initiatives by identifying significant sources of process variation and implementing corrective action using team-based problem solving techniques. He also reduced cost of poor quality by over 3.5% of Standard Cost of Production through reduced customer complaints and process improvement to reduce scrap and off-standard product.
Mr. Cutrell possesses a BS, Industrial Management from The Ohio State University and an MBA from Murray State University. He is also a member of the American Society for Quality since 1973 and has been a Certified Quality Engineer since 1976.
close biographyDaniel is an Associate of The ACCESS Group (TAG) with over twenty-five years of experience in operational and leadership positions. His operational experience includes extensive involvement in logistics; materials management; purchasing from capital buying, operations, to MRO; systems integration and implementation; personnel training and staff development; production control; inventory control; lean techniques in manufacturing, and supplier development. Daniel has held numerous positions within operational organizations from the shop floor to the executive level. Daniel has worked in industries including, automotive, heavy truck, appliance, metal stamping, gray-iron foundry, machining, injection molding, free brass rod, warehousing and distribution, and others in both consulting and full time positions. Companies that Daniel has worked with include Navistar, Tower Automotive, PMI Food Equipment, Aeroquip, Chase Brass, Marathon Electric, Bosch, and Life Cycle Engineering.
Daniel has managed many projects over his career ranging from multi-plant materials management, production control start-up implementation, to lean manufacturing techniques to meet daily release requirements of an automobile supplier. Some of his accomplishments include managing the immediate supplier replacement of castings after a disastrous foundry fire without loss of a single customer or loss of production. He also managed and directed Just-In-Time daily shipments by a Tier 1 automotive supplier by initiating with Ford a “milk run” concept, still in use today that consolidates shipments of multiple suppliers from the US to Canada and ships the LTL of many suppliers with one full load price. Daniel led a plant reliability excellence project for a major supplier of automotive -the heavy truck assembly industry, which resulted in Kitting, reduction of inventories of 20%, more effective scheduling, and a Daily Management System. He implemented a pull/Kanban manufacturing system for an electric motor manufacturer that increased on time deliveries and completed shipments from 65% to 98%. He also has increased product throughput by 35%. Other accomplishments include improvements of inventory accuracy from 82% to 99%, supplier reductions from 1200 to less than 350, and improvements in supplier deliveries from 60% on time delivery to 98%.
Daniel interacts well with people from all levels of the organization which has been instrumental in the successful projects he has led. Daniel's involvement in the value stream includes all facets including business strategic plan development, managing startups, developing lean plant layouts, establishing Kitting for maintenance work orders, conducting management and employee training, plan implementation, production control, establishing key performance measurements, and sustaining ongoing operations. He is intimately familiar with JIT and sequencing for the automotive industry, pull and Kanban systems, cellular and single piece flow manufacturing processes, level loading, and other lean manufacturing principles. Daniel is an enthusiastic leader that gets results by involving and teaching the people he works with in order to ensure success both during the implementation and after his engagement is complete.
Daniel’s educational background includes a BS degree from Indiana University in Bloomington, Indiana, and holds an MBA from Xavier University in Cincinnati, Ohio. Daniel is APICS certified at the CPIM level. He is also certified at the CPMM level from AFE (Association of Facility Engineering). Daniel is currently a member of Strathmore’s Who’s Who International, and is a published author in the field of materials management. He has served numerous positions in APICS, including three years as President of the Fort Wayne, Indiana APICS chapter. He is also a certified instructor for CPIM courses.
close biographyDavid Duncan is an associate of The ACCESS Group (TAG) 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:
Marvin Eades has over 30 years experience in manufacturing and tool engineering. He has held key technical, industrial, and manufacturing roles with companies such as Contour Technologies, US Army–Department of Defense, A-Square Company, D&M Machine and Tool Company. In addition, his consulting expertise has been employed by such industries as United Technologies, Caradon, Ford Motor Company, Southern Pride, Cessna Aircraft, Woodward FST and Duracell.
Marvin is an accomplished project manager with many successful plant relocations to his credit. His experience allows him to work comfortably in both a management capacity as well as in a hand-on environment. Marvin has been responsible for tool design, development, and maintenance in numerous industries and processes. This includes experience in industries and processes such as automotive, appliance, defense, ammunition testing, metal forming, metal and aluminum roll forming and stamping, machine-building products, consumer goods, and furniture. He is experienced in a wealth of different areas such as training manuals, quick-change tooling, fixture design, ergonomics, preventative maintenance, plant management, production scheduling and procedures, process flow development, machine operations, and cellular manufacturing. He has been instrumental in designing machines and equipment to increase throughput and to improve operational capabilities. He is familiar with improve process flows and developing user-friendly operations to improve productivity. Marvin is a results-oriented professional who readily identifies ideas and methodologies to help operators improve efficiencies and throughput. He has had a broad range of experience in product development and test fixtures.
Marvin holds an AAS degree in Organizational Leadership and a BS degree from Purdue in Industrial Organization and Management with a minor in Mechanical Engineering Technology. He the holder of a US patent for fixture design and has several patents pending. Marvin was a Helicopter Crew Chief an Officer, Company Commander, Pathfinder, Long Range Reconnaissance Patrol and Airborne Ranger while in the US Army and was part of the Mechanized Infantry Division. In addition, he served as Battalion and Brigade Information Offices and Brigade Adjutant Officer.
close biographyLloyd Eismeier has over 30 years of operational and consulting experience in manufacturing operations, plant management, manufacturing engineering, industrial engineering, project management, and plant engineering. Lloyd’s experience was gained in a variety of industries including appliance, automotive, steel furniture, HVAC, and metal products industries. This includes experience with companies such as Maytag, Steelworks, Goodman Manufacturing, Stainless Metal Products, Superior Essex, General Electric, Duracell, Aladdin, Eclipse Aviation, and Cessna.
Lloyd has a proven record of success in “hands-on” engineering positions and various levels of management and has very strong organizational, planning, presentation, and communications skills. He has performed as a project manager in many roles including plant relocations, plant startups, and installation of new processes in existing facilities. Lloyd has overseen numerous capital projects, including the design and planning of manufacturing facilities and has successfully managed the myriad of challenges involved in the plant startup and shutdown process. Lloyd has a track record of innovation in cost reduction, quality systems, and productivity improvement programs. Lloyd is experienced in designing work cells, developing plant layouts and defining efficient manufacturing processes and production flows from a lean perspective. In his experience with planning, scheduling, and managing the many tasks involved in plant refurbishments, startups and relocations, he brings a keen sensitivity for production. Lloyd is experienced in working with contractors and suppliers and in developing equipment requirements and effectively justifying and managing the expenditure of capital funding. Lloyd is also highly experienced in designing and implementing material management programs, scheduling systems, and warehousing plans. He is highly skilled at justifying, designing, procuring and installing wet and dry finishing systems. He is proficient in nearly every aspect of powder paint systems, from designing, developing, and purchasing to installing, analyzing, maintaining and supervising.
Lloyd has a Bachelor of Science degree in Industrial Management from the University of Maryland and pursued engineering graduate studies at Johns Hopkins University.
close biographyRichard Ferguson is an Associate of The ACCESS Group (TAG) and has over 20 years of experience in operational and management positions. His operational skills include extensive experience in plant start-ups, product launches, and continuous improvement initiatives. Richard also has experience in lean enterprise methodology, plant consolidations, material management and quality implementation. Richard has held positions from entry level in the Production Control area to senior management positions such as Plant Manager and Director. Richard’s experience includes positions with manufacturers such as Ford Motor Company, Nissan Motor Manufacturing Corporation USA, Delco Remy and Commonwealth Industries.
Richard assisted with the startup of the Ford Motor Company transmission plant located in Batavia, Ohio and the startup of the initial manufacturing assembly plant for Nissan USA in Smyrna, Tennessee. Some of Richard's accomplishments include creating a lean assessment-rating document to assist in the analysis of lean enterprise objectives. While operating as plant manager at Delco Remy, he was able to reduce raw material inventory from six days to one and one half days, reduce overtime from 30% to 2%, reduce specific changeover times by 50%, and able to reduce finish goods inventory while supporting customers daily on-time requirements. He led the closing and consolidation of two facilities resulting in savings of over $500,000. He was also able to reduce the OSHA lost time incident rate from 9.2 to just 2.0 and the lost workday rate fell from 198.7 to 34.2. He has helped achieve certifications in both ISO and QS programs. Richard was part of the team that co-coordinated planning and training efforts to effectively launch the three crew operations for the Ford Super Duty pickup truck plant. He worked closely with Ford engineering and the UAW to make assembly line improvements that resulted in manpower reduction of 28 positions. While at Nissan, Richard served as a project manager for the Nissan truck launch of 1993 that included travel to Japan for trial build of the vehicle. The launch was successful and on schedule.
Richard is an easy to approach and attentive leader with excellent communication skills that allow him to interface effectively with people from all levels of an organization. He understands what it takes to start up a plant or revamp the operations to make sure that the manufacturing process flow is efficient and able to support customer requirements. He understands the importance of developing and monitoring metrics relating to quality, cost, delivery, and safety. Richard knows the importance of developing standardized operations along with maintaining a pro-employee environment through consistent communication and management.
Richard’s educational background includes a BA degree from Winston Salem State University, Winston Salem, North Carolina.
close biographyMr. Tom Gibney is an Associate of The ACCESS Group (TAG) with over thirty years of experience in various industries including automotive, aircraft, HVAC, electronics, mining, and general industry. He has held positions of industrial engineer, manufacturing engineer, facilities engineer, and design engineer, both as a practitioner and a manager of these functions. Tom has worked with companies such as Navistar (International Truck and Engine), Carrier Corporation (a United Technologies Company), Aeroquip, Gulfstream Aviation, Aerostructures, Seimens, Gillette, Columbus McKinnon, and Emerson Electric.
Tom possesses extensive experience in productivity improvement, plant layout, establishing work processes, capital planning and budgeting, inventory management, supply chain analysis, LEAN manufacturing, material handling, setting up cellular manufacturing systems, establishing kanban systems, line balancing, sequencing and kitting, work measurement, costing, project management, programming, capability analysis, and resource utilization.
He has been involved in new product launches, site relocation, and product re-designs. His experience is in a variety of operations including machining, assembly, fabrication, and molding. He has participated in achieving (or maintaining) various quality certifications such as ISO9000, QS9000, Nuclear “N” Stamp, and various NAVSEA and MIL-spec programs.
Tom is an advocate for change and has superior mentoring and teaching skills. He has excellent interpersonal and analytical abilities. His computer skills include MS Office, Autocad, MS Project, Visio, and various MRP programs. He is a seasoned professional who is equally effective as a team member, team leader, or individual contributor.
Tom is a graduate of the Illinois Institute of Technology in Chicago. His major course of study was industrial engineering. He has also successfully completed many advanced training courses in industrial management, ergonomics and safety, and technical areas. He is a senior member of IIE and certified in MOST.
close biographyRay Gil is a quality assurance professional with proven and well developed technical and organizational skills. These include Program/Process Quality and Supplier Quality experience (commercial and aerospace), metrology (inspection and calibration), statistical & process control skills (SQC, SPC, FMEA, Six Sigma processes), and technical staff training. He has worked for companies such as Cummins Engine, Caterpillar, Hughes Aircraft, Aerojet-Gencorp, Johnson and Johnson, Baxter Medical, AG Nobel-Akzo, Garret Hydraulics, Lockheed Martin Aerospace. He has also worked directly on projects with NIST, IMGC (Italy’s national bureau of standards-Turin), and CENAM (Mexico’s National Bureau of Standards-Queretaro).
As a quality professional he has prepared project proposals, managed budgets, and performed both classroom and on-the-job training for quality and manufacturing personnel. He has managed quality engineering departments and laboratories and has coordinated, and performed internal audits. He is familiar with the requirements of many ISO, ANSI, ASTM, ASME, and Military Standards. His quality engineering experience covers physical/mechanical, dimensional and electrical metrology (length, mass, force, temperature, pressure, material testing (hardness, tensiles, etc), surface texture and geometrical analysis. He is also experienced in geometrical dimensioning and tolerancing (GDT) and coordinate metrology. Ray’s skill base includes knowledge of various machining processes (milling, turning, broaching, grinding, honing, lapping); also, investment casting and forging processes (Iron, Aluminum, and Steel alloys). He is also familiar with heat treating, brazing, and hipping operations, NDT/NDI, coatings, and metallurgical inspections. The scope of his responsibilities has included supplier quality assurance activities and product source acceptance at vendor’s facilities (piece parts and assemblies). Ray has been an active participant in NCLSI committees on pressure standards and calibration procedures development. He has developed ISO 9000 based quality management system (one of these approved by the FAA) and ISO compliant calibration procedures for a number of industries in various disciplines of metrology. In addition, he is licensed by the FAA as a designated airworthiness engineering representative (DAR) for aircraft power systems (jet engines), and is an ISO 17025 Metrology Laboratory Sr. Lead Assessor.
Ray’s experience in supplier quality assurance (SQA) is rather extensive in both the automotive and aerospace industries. This has included three manufacturing start-ups (one automotive, and two aerospace). One of his major accomplishments as a principal engineer for CONSOLIDATED DIESEL, a CUMMINS ENGINE company was the successful start-up of a 1.25 million square feet diesel engine manufacturing facility in Whitakers, North Carolina. Responsibilities included facility planning, systems development, staff selection and training, supplier qualification, transfer lines machine run-offs, gage and tooling qualification. He was instrumental in the creation, and was a very strong contributor, of a corporate metrology council which provided guidance and leadership in metrology to all CUMMINS ENGINE facilities worldwide (US, Europe, South America, India, and China).
His professional education is in Engineering Physics and he has a background in precision measurements (PMEL) from the US Air Force. He is entirely fluent in Spanish and knows conversational Italian.
close biographyBob Hansen is an Associate of The ACCESS Group (TAG) and has over twenty-three years of experience in leadership positions supporting manufacturing operations. His experience includes extensive involvement in benchmarking maintenance and engineering best practices and facilitating implementation of Overall Equipment Effectiveness (OEE) metrics and productivity improvements. Bob was an engineering and maintenance department manager supporting manufacturing organizations from raw material flow through conversion to finished goods. Bob participated on global manufacturing teams reviewing manufacturing locations in 6 countries. He has worked in industries including photographic films and papers, aerospace, appliance, metal forming, machining, non-woven textile, petroleum refineries, pharmaceuticals and others in both consulting and full time positions. Companies that Bob has worked with include Eastman Kodak, Fiberweb Non-wovens, Roper Industries, Tesoro Petroleum, General Chemical, Aventis Pasteur, Ball Aerospace Testing Center and Alcoa North American Primary Metals among others.
Bob has provided equipment system reliability leadership in many different assignments throughout his career. He has lead quick changeover programs for both production operations and maintenance activities and champions conditioned based maintenance using predictive technologies. One major success story was the 45% reduction in unplanned equipment downtime (over 300 downtime hours reduction), as well as reducing annual shutdown schedules by 10 days of a major manufacturing machine generating over $500 million of product annually.
Bob is recognized as a leading authority on OEE and is author of ‘Overall Equipment Effectiveness: A Powerful Production/Maintenance Tool for Increased Profits’, New York, New York: Industrial Press, 2001. This book provides guidelines for OEE implementation, data collection and analysis. It has over 26 ‘tools’ for loss elimination. It includes sections on designing for reliability and formulas for equipment system acceptance testing. He provides reliability block diagramming analysis of equipment systems to evaluate availability and risk assessment. Bob has presented papers about OEE at 5 national conferences and written two articles for Maintenance Technology magazine.
Bob has managed and facilitated various sized groups and departments from shop floor work groups to global leadership teams. Bob understands the four phases of situational leadership and applies appropriate directing, coaching, mentoring, and monitoring skills depending on the development stage of individual teams.
Bob’s graduated from the University of Wyoming with a BS degree in civil engineering. He is a registered Professional Engineer in Colorado and Tennessee. He is a member of the Society of Maintenance Reliability Professionals and a Certified Maintenance Reliability Professional (CMRP).
close biographyBill Hardin is an associate of The ACCESS Group (TAG) and has over thirty years of technical and leadership experience. His experience includes increasingly responsible positions in maintenance, process engineering, methods and standards, quality, production management, plant management, to later held corporate responsibilities as Director of Manufacturing for nine plants spanning the United States. He has worked in a wide variety of industries including machine tools, crane and hoist manufacturing, aerospace, automotive, office furniture, recreational vehicles, telecommunications equipment, and others. Companies that Bill has worked for include Bendix/ Allied Signal, Duff Norton, Gentz Aerospace, and Haworth, Inc. He has performed a number of supplier assessments for both Ford and DaimlerChrysler.
Bill has led a wide variety of projects during his career including the total start up of an aerospace (turbine component) plant, a major expansion and profit improvement project of an older office furniture plant, the restructuring and financial turnaround of a telecommunications equipment manufacturer, and a major profit improvement ($7 million) project in a motorhome manufacturing facility. Additionally, he has led the consolidation of a number of small office furniture manufacturing plants while simultaneously implementing lean manufacturing initiatives and a new Oracle database.
Bill’s years as a shop floor supervisor, plant production manager, and plant manager
provided him with a unique ability to assess technical, systems, and managerial situations quickly and formulate effective solutions that improve results. He has led plants to radically improved profitability through his effective integration of people and processes and his ability to establish effective metrics and accountability. His plants have won recognition and awards for customer service, profitability, and community service.
Bill’s education includes a BS degree in Engineering Operations from North Carolina State University as well as a later earned Master of Business Administration from the University of North Carolina at Charlotte. He served as a maintenance officer in the US Air Force, where he trained and evaluated maintenance teams in complex weapons systems. Bill has additional formal training in ISO/QS systems, Total Preventative Maintenance, Demand/Pull Systems, and Union Free Philosophies. He is a member of the Institute of Industrial Engineers.
close biographyMr. Toby Heckaman is an Associate of The ACCESS Group (TAG) and has over twenty-seven years of experience in operational and leadership positions. His operational experience includes extensive involvement in manufacturing management, lean manufacturing, systems development and implementation. Toby has held numerous positions within operational organizations from shop floor management to the executive level. Toby has worked in industries including automotive, metal forming, machining, assembly operations as well as materials in both consulting and full time positions. Companies that Toby has worked with include Bendix, Allied Signal, BJKC, Bosch and York Casket Co.
Toby has led many projects over his career ranging from complex manufacturing designs and implementation to lean manufacturing conversions of plant wide operations in many different industries. Some of his accomplishments include designing using autocad14 a new plant from start to operational, managing the relocation to that plant with a new Joint Venture between an American and Japanese automotive Company, the relocation of assembly operations from the US to Canada, and the relocation of operations from Indiana to Tennessee. Toby has implemented a kanban manufacturing system, visual factory, assembly line visual changeover sheets and finished inventory goods storage to eliminate missed shipments. This system led to on time delivery of finished product to all automotive customers to 100% on time delivery for more than 10 years. He has also managed the restructuring of a wood casket manufacturing facility from departmentalized production to lean continuous flow processes which reduced product cost by 20% across the plant.
Toby interacts well with people from all levels of the organization which has been instrumental in the successful projects he has led. Toby’s lean plant layouts, employee training, plan implementation, performance measurements, and ongoing operations has lead to numerous plant awards from many automotive plants, such as Nissan, Toyota and Isuzu. He is intimately familiar with JIT and the automotive industry, kanban systems, cellular and single piece flow manufacturing processes, level loading, and other lean manufacturing principles.
Toby’s manufacturing, kanban, JIT, process flow and Kaizen abilities came from training in Japan as well as the US. He has attended several classes in Time Management, Leadership Workshops, Taking Control of Time Management and several Quality Training classes. Toby is well versed in Excel, Word and Autocad. During his tenure with the US Army he was a qualified Radio – Radio Teletype operator and with a Secret Clearance. Tour of Duty was in Vietnam. After 2 years of service he left the Army with an Honorable Discharge as a Specialist 4 Grade.
close biographyTom Jackson is an Associate of The ACCESS Group (TAG) whose Fortune 100 experience is balanced with a strong background in smaller to mid-size “wear many hats” manufacturing management. He has demonstrated transformational leadership for over 20 years in production environments from high volume to low volume and engineered-to-order. Tom has worked with industries including aerospace, automotive, heavy industrial equipment, metal forming, machining, injection molding, remanufacturing, medical instrumentation, and others in both consulting and full time positions. Companies that he has worked with in both consulting and full-time roles include Camau-Pico, Clarion Technologies, Eaton Aerospace, Eaton Hydraulics, Falk, Melling Automotive, Rexnord, and Stryker Medical.
Tom’s depth of knowledge across all manufacturing functions from strategy planning and finance, to marketing and engineering, to quality systems and tooling, to assembly and logistics, give him the background required for leading cross-functional teams to achieve major Lean improvements across the whole value-stream. As a division manager he provided the change-agent leadership in the turnaround of an aerospace machining facility batch manufacturing with a low single digit bottom-line to a best-in-class Lean Enterprise with strong double-digit EBITDA. He has also led and mentored Advanced Manufacturing Engineering teams whose Lean Six Sigma projects have resulted in millions of dollars of demonstrated cost-savings. Tom is seasoned at using all the Lean tools in Kaizen events that have brought sustainable improvements to over 40 facilities. His “hands-on, go see” approach is user friendly for top executives and manufacturing floor operators alike.
Tom’s educational background includes Mechanical Engineering at Michigan State University and a Bachelor of Business Leadership from Baker College in Flint, Michigan. He has numerous certifications in Lean Sigma tools including Value Stream Mapping, Standardized Work, Pull Systems, Set-up Reduction, 5S, Visual Controls, Variation Reduction Kaizen, and Strategy Deployment. Tom has developed Lean training material which is in use at companies from small job shops to major corporations.
close biographyMr. David Krebs is an Associate with The ACCESS Group with over twenty-six years experience in the automotive industry. David has held positions such as President, Plant Manager, Director of Product Planning and Program Management, Product Manager, Senior Engineer, Project Engineer, and Senior Staff Engineer. David has worked with companies such as BJKC-Americas Corporation, AlliedSignal/Bosch and AlliedSignal.
David is an experienced and successful manufacturing executive with applied knowledge in engineering, marketing, operations and corporate leadership. He has demonstrated the ability to integrate and leverage all business functions into a high performance operating team. David has proven capabilities in improving competitive position, profitability, market share, and overall organizational performance. While working with BJKC, he reduced operating costs by over 6% each year through aggressive support of Kaizen activities. David has achieved and maintained QS-9000 and ISO-14001 certification. He received Nissans’ “Quality Master Award” on three occasions. David has directed the start up and expansion of plants as well as directed extensive relocation projects. Through his career, David has strategically and tactically implemented plant cost containment and profit maximization initiatives, at one point totaling over $8.7 million in two years.
David received his Bachelor of Science degree in Mechanical Engineering from the University of Detroit. David went on to complete a Masters in Business Administration at the University of Notre Dame.
close biographyMarshall, a Six Sigma Black Belt serves as HPP’s Director of Project Support has overseen numerous Lean Healthcare client engagement. As a former multiple year “top-ten percent” performer at General Electric, Marshall brings clients the much needed tools and techniques needed in any industry, including healthcare. Marshall is also a graduate of General Electric’s Operations Management Leadership Program; he has experience in various supply chain capacities including quality engineering and global sourcing for both GE and Procter & Gamble. Marshall has led cross-functional Lean and Six Sigma teams in North America and Europe with a track record of delivering process improvements and bottom line results. In addition, he brings a strong Lean background coupled with experience in Kaizen facilitation, Lean Enterprise implementation and Six Sigma application. Marshall worked side by side with former Toyota Japanese Sensei’s in identifying, developing solutions, and overseeing implementation of waste reducing systems and much improved processes throughout value streams. Marshall’s expertise in both Six Sigma and Lean enables him to apply a broad spectrum of process improvement tools tailored the healthcare industry’s needs. He holds a degree in Industrial and Systems Engineering from the Georgia Institute of Technology (Georgia Tech).
close biographyBill Lowstuter has over 28 years of experience in manufacturing. He has held senior level positions including program manager, director of research and development, vice president of operations and chief executive officer/president, officer and board of directors. His technical, management and leadership skills have been demonstrated with such companies as Ingersoll-Rand, Rexham Corporation, Culbro Machine Systems, Speed Queen, Pressed Steel, and Grimes Aerospace.
Bill has been involved with and worked in a variety of industries including microprocessor controls, heavy equipment, machinery, consumer goods, metals, aerospace and others. His skills and talents in the area of maximizing productivity through the development and implementation of Kaizen and lean manufacturing principles are superior. With Bill’s leadership and the implementation of Kaizen events, numerous companies have seen revenues grow in excess of 20 percent while operating costs have been reduced by 30 percent or more. Bill’s accomplishments have led one industry to a reduction of $2 million in labor costs or 24 percent, increasing plant capacity by 280 percent within the same footprint, reduction of inventory by $4 million, defects by 64 percent all while increasing profits by $400,000 per annum. Bill’s multi-disciplined background includes direction over functional organizations such as manufacturing, finance, quality assurance, materials management, purchasing, environmental, health and safety, and human resources. His experience in these areas provides a unique perspective that allows perfect complimenting between strategic and tactical plans. Throughout Bill’s successful executive career he has consistently developed and implemented manufacturing, engineering, material and quality programs that have increased plant capacity, improved productivity and generated short and long term revenue and profit gains.
Bill has a Bachelor of Science degree in Electrical Engineering from the University of Illinois. He has conducted numerous seminars in Kaizen principles and lean manufacturing.
close biographyDennis McCully is an Associate of The ACCESS Group (TAG) and has over twenty-four years of experience in product engineering design and management, program management, and quality positions. Dennis has held numerous positions within organizations from design engineer to program manager to department supervisor. Dennis has worked in industries including automotive, heavy truck, injection molding, and others in both consulting and full time positions. Companies that Dennis has worked with include United Technologies, Rockwell Automotive, Arvin Meritor, and others. Dennis has also performed over 200 lab accreditation assessments for testing laboratories both in the US and internationally.
Dennis has led many projects over his career ranging from extensive involvement in product design, product testing, production support, program management, quality checks in support of quality control plan, validation activities in support of PPAP submission, and customer approvals of production parts. Some of his accomplishments include managing the release of new products as part of a Tier 2 automotive supplier with multiple plants in the US. He also managed Canadian suppliers of tooling, acoustic noise measurement and reduction. Dennis has been responsible for a new testing lab set-up and all testing responsibilities. This included the CAD and documentation systems for product engineering, and acting as QS9000 management representative for product engineering including writing and publishing procedures. He also prepared and secured lab accreditation to ISO 17025 for an automotive products lab for a tier 1 automotive supplier. Dennis has supported product transitions from one plant to another both in program management and testing activities for re-validation. Dennis has provided and implemented numerous cost savings for production products. Dennis has designed and implemented a new insulation system for small electric motors resulting in a 50% work in process saving for numerous products. Dennis has also participated in lean manufacturing activities resulting in 60% reduction of work in progress and a 70% reduction in product travel within the manufacturing facility. Dennis has provided quality engineering support for PPAP submissions for a Tier I supplier including control charts, Cpk, Ppk and supporting statistical analysis. Dennis has provided training classes on various topics including estimation of measurement uncertainty, electric motor design and quality system/procedure rollout training.
Dennis interacts well with people from all levels of the organization, which has been instrumental in the successful projects he has led. Dennis’s experience includes all facets including business plan development, assistance with the budgetary planning, product design, product testing, employee training, plan implementation including international considerations, performance measurements, and ongoing operations.
Dennis’s educational background includes a BS degree from Mississippi State University in Starkville, Mississippi. He is also a laboratory assessor and is qualified as a senior/lead assessor for ISO/IEC 17025. Additional training includes: Program Management, Kaizen – business process improvement, Lean Manufacturing, Leadership in Transition, and Lead Assessor Training.
close biographyMr. Jim McKeever is an Associate of the ACCESS Group with over twenty-five years of experience in various industries including glassware, appliance and automotive. Jim has held positions as industrial engineer, engineering manager, quality manager, quality director, business unit manager and general manager. Jim has worked for companies such as Del-Met, Norris Industries, Sheller-Globe, International Harvester, Frigidaire and Libby Glass.
Jim possesses strong management skills and has directed organizations with more than 350 employees with as many as 10 direct reports. Jim has directed areas including manufacturing, quality, design, tooling, quoting, product engineering, process engineering, accounting, program management and sales. Jim has worked with many different technologies including injection molding, glass forming and decorating, stamping, welding, plating, decorating of plastics, vibration welding, heat staking, ultrasonic assembly, hand and automated assembly, painting and hot stamping. During his time as business unit manager Jim was responsible for growing his account from $12 million to $45 million. Jim directed the implementation of QS9000 at three production facilities and a supporting technical center. He has developed programs and coordinated program launches for GM, Honda, Mercedes, Nissan, Ford, and Chrysler as customers. Jim’s background includes quality planning tools such as DFMEA, PFMEA, PPAP, GD&T, Process Flow, Control Plans, SPC, SQC, DOE and Metrology. He is well versed in many problem solving techniques and has extensive experience with 8D. Jim’s engineering background includes design, product engineering, industrial engineering, process engineering, manufacturing engineering, tooling and secondary fixtures. Jim is both a problem solver and implementer.
Jim’s studies were at the University of Toledo where he received a Bachelor of Science degree in Industrial Engineering and at Wright State University where he received a Master of Science in Systems Engineering. Jim is also a registered Professional Engineer in the state of Michigan.
close biographyDavid Pickens has over 10 years experience in the areas of quality, operations and management. He is a results-oriented, global professional with strong leadership skills complemented by demonstrated strengths in strategic planning, situational analysis, financial analysis, training, technical applications and process integration. He has held key positions with Magnatek, Allied Signal and Matsushita Refrigeration.
David is a highly skilled "out-of-the-box" thinker with the ability to motivate and empower associates through human resource and change management strategies. He is an expert, and taught others, the skills of lean manufacturing, Six Sigma, Statistical Quality Control (SQC), Total Quality Through Speed, Industrial Statistical Methods, ISO9000, and Total Improvement Methods. He has served as the Operational Excellence Business Manager for a company's 435 Black Belts, 9 Master Black Belts, 48 lean manufacturing engineers and 35 supply base engineers. Previously, David has developed Train-the- Trainer certification programs for all Point-of -Use Training modules as well as managed multi-million dollar operations and budgets. He has been responsible for the coordination of standardized business policy implementation, and has led repositioning teams in the closure and relocation of manufacturing processes. He has worked with, and trained, Demand Flow Technology teams to improve overall product chain productivity, efficiency, cycle time and cash flow; implemented and taught econometric and financial forecasting business models for strategic planning; and managed a $22 million Cost of Goods Sold model plant project resulting in a 100 percent productivity increase, while cutting required manufacturing space by 45 percent.
David attained his MBA, with a concentration in strategic planning and international trade and finance from the Heriot-Watt University in Edinburgh, Scotland. The Economist Intelligence Unit ranked the school in the Top 50 MBA schools internationally. He also holds a BS in Statistics from the University of Tennessee.
close biographyKevin Plott is an Associate of The ACCESS Group (TAG) and has over seventeen years of professional experience in operational and leadership positions. His operational experience includes extensive involvement in process and quality engineering, equipment and facilities maintenance, project leadership, systems development and implementation, personnel training, and process capability improvement. Kevin has held a wide variety of professional positions in manufacturing ranging from process and quality engineer to leadership of major capital projects and organizational leadership of maintenance, facilities, and tooling functions. Kevin has worked in the appliance industry for over 25 years among two manufacturing sites within Whirlpool Corporation.
Kevin has led many projects over his career ranging from complex manufacturing and quality systems design and implementation, comprehensive maintenance master plan development and implementation, process capability improvements, to plant-wide lean manufacturing initiatives. Some of his accomplishments include development and implementation of an ISO 9002 certified quality system, development and implementation of a comprehensive maintenance master plan involving system creation of work order, planning and scheduling, PM program, craft training program, performance metrics, root-cause failure analysis, and new equipment reviews. He also led his plant’s 5S and TPM programs. His TPM efforts on his plant’s automated oven cavity fabrication line (Scott Line) resulted in a 49% to 75% improvement in Overall Equipment Effectiveness. Kevin was also site leader for a corporate-driven process capability improvement initiative targeting critical process and product characteristics, with efforts driving solid improvements in capability indexes.
Kevin’s involvement in the value stream includes all facets including business plan development for maintenance systems, lean assembly line layouts, employee training, plan implementation, performance measurements, and ongoing operations. Kevin is an enthusiastic leader that gets results by involving and teaching the people he works with in order to ensure success both during the implementation and after his engagement is complete.
Kevin’s educational background includes a BS degree from Bowling Green State University in Bowling Green, Ohio majoring in Manufacturing Technology and holds an MBA from the University of Mississippi in Oxford, Mississippi. Kevin is also a certified Six Sigma Black Belt through Whirlpool Corporation’s Operational Excellence program and Six Sigma Associates, Inc.
close biographyWayne Scarberry is an Associate of the ACCESS Group (TAG) and has over twenty-five years of extensive experience utilizing the principles and concepts for lean enterprise with the Development, Manufacturing and Testing environments involving Product support, R & D, and all other Administrative areas. Wayne has held numerous positions within engineering and manufacturing areas and then site lean leader to corporate lean leader. His background is in the automotive industry working with Bendix Brakes, Allied / Signal and Robert Bosch Corp.
Wayne has lead and been involved in many projects over his career from complex engineering test laboratory design and manufacturing system design. Some of his accomplishments include developing a TPM / 5S system for engineering test laboratories across Bosch Chassis Systems, which decreased unplanned down time by more then 92% in 18 months. He’s been involved in leading projects in the consolidation of eight manufacturing sites to five in North America and Mexico. Wayne has worked extensively with manufacturing support functions & the supply base in cost savings activities which have yielded close to $1 million in savings in the first year. He has lead lean line design activities which have increased OEE from 65% to 87% within the first four months of improvements by applying TPM / 5S and natural work teams. Wayne was part of a design team which designed and developed an associate involvement system which has generated over 5000 implemented improvement ideas over the past seven years.
Wayne has been involved in policy deployment, lean strategy /deployment and visioning exercises working with upper management. He has an in-depth understanding of the Toyota Production System principles and concepts and has a passion for lean. He has lead several kaizen events which include VSM, SMED, TPM/5S, Error Proofing, Supervisor Development, Problem Solving, Lean Line Design, Design for Mfg., Standard Work, and Transparent Processes. Wayne utilizes a hands on approach when teaching and applying lean tools; he is an enthusiastic leader and gets the results by involving and engaging those associates who he comes in contact with. He ensures success by establishing real targets and measures that can be achieved by the associates and team in regards to set expectations.
Wayne is currently pursuing his BS degree in Operational Management from the University of Berkley, Michigan and scheduled to complete summer of 2008. Wayne has achieved several lean and management certifications from Indiana University, Ivy Technical College South Bend, Indiana, Harris Lean Systems North Carolina, Kaizen Institute and Robert Bosch Corporation. Wayne also is a veteran serving four years on active duty in the United States Marine Corps.
close biographyMr. Steve Schmidt is an Associate of The ACCESS Group with nearly twenty-eight (28) years of manufacturing and quality experience in the machine tool, aerospace, consumer goods, and automotive industries. Steve has held positions as Project Manager, Manufacturing Engineer, Engineering Manager, Quality Systems Manager, and Vice President of Manufacturing. Steve has worked with companies such as Kearney and Trecker Corporation, AlliedSignal Aircraft Landing Systems, Perfect Equipment, Wellington Cordage, Landis & Gyr, Outdoor Lighting Perspectives, and ArvinMeritor Tower Automotive, and Clarcor Air Filtration Products.
Steve possesses strong technical, problem-solving, and organizational skill in both the manufacturing and the quality aspects of heavy industry. As a project manager he has coordinated multiple US plant closures and shipment of equipment and raw materials to Mexico and China. Responsibilities included preparing the export documents package, coordinating container shipments, and on-site project management of the closure and clean-up process. Steve has also developed plant layouts using lean manufacturing concepts, one in conjunction with moving an electrical metering plant from the US to Mexico. Steve started his career by serving a four (4) year machinist apprenticeship, learning all aspects of conventional and CNC machining. Steve moved into Manufacturing Engineering, specializing in the processing of gears, machine tool spindles, and aircraft wheel and brake components. He has a working knowledge of lean enterprise tools and has been involved with implementation of cellular manufacturing, optimizing process flow, and designing manufacturability into products and tools. His management development began by supervising a stamping, “Dacromet” coating, and tool room operation. Steve has been involved in equipment purchasing, specification, and implementation. Steve moved into the quality arena by implementing an SPC data collection system and managing the implementation of a comprehensive QS-9000/ISO-9001 quality system. He is familiar with the development of quality system procedures, flow charts, and in optimizing forms and operating procedures. Along with managing Quality System activities, Steve has written D/PFMEA’s, control plans, and PPAP’s. Steve was a member of the team responsible for implementing ISO-14001 EMS. Steve’s management experience culminated in his position of Vice-President – Manufacturing in which he held responsibility for all production, engineering, quality, and maintenance departments, including 3-shift plant supervision. Steve possesses some specific product design experience and was issued two (2) patents for his designs. He is a seasoned professional who portrays both hands-on and strong leadership skills.
Steve earned his B.S. degree in Mechanical Engineering Technology from Purdue University – Calumet and an A.A.S. degree in Mechanical Design Engineering Technology from Milwaukee School of Engineering, graduating from both with honors. He also successfully served a four (4) year machinist apprenticeship at Kearney and Trecker Corporation. Steve has completed extensive training in management of QS-9000, ISO/TS-16949, and ISO-14001 EMS standards, and is a QS-9000/ISO-9001 Lead Auditor.
close biographyBob Sproull is an Associate of The ACCESS Group (TAG) and has over thirty years of diversified experience in operational and executive leadership positions. Bob’s experience centers-around continuous improvement utilizing his unique blend of Lean, Six Sigma, and the Theory of Constraints to drive profitability. He has had extensive involvement in operations, quality, engineering, quality systems (ISO, TS, QS) and supplier development. Bob has occupied numerous positions within manufacturing organizations at the shop floor, management, and executive levels and is known for his passionate approach to lean and continuous improvement. He has worked in a variety of industries that include aerospace, automotive, heavy truck, fiber glass, metal forming and machining, injection molding, assembly, extrusion, and others in both consulting and full time positions. A partial list of companies Bob has worked with includes Xerox, Michelin Tire, American Sunroof, the USPS, Teksid Aluminum, Engineered Fabrics Corporation, Morgan Truck Corporation, Autocam, Caledonia Group, and others.
Bob has extensive operational assessment experience and has led numerous projects throughout his career. He has widespread domestic and international consulting experience and is well respected by his clients and peers for his knowledge of and hands-on approach to Lean, Six Sigma, and the Theory of Constraints. Bob is an excellent problem solver who has had one manuscript published (Process Problem Solving – A Guide for Maintenance and Operations Teams – Productivity Press, Inc. 2001). Bob’s second book, on the integration of Lean, Six Sigma, and the Theory of Constraints, will be released later in 2008 by Productivity Press, Inc.
Bob has led or participated in numerous Lean and TPS transformations in both manufacturing and transactional processes. A partial listing of Bob’s improvement accomplishments include a reduction in engineering lead time on new order quotes from 40 days to 48 hours for a truck body manufacturer; improvement in equipment reliability from 56% to 80% in 3 months for a plastic bottle manufacturer; an inventory reduction of $3 million in 2 months for a bus manufacturer; EBITDA improvement from 15 to 41% and a PPM reduction from 20,000+ to 200 in two months for a European OEM tier one precision component supplier; a $1 million EBITDA turn-around in four months in an OEM fiberglass parts manufacturer.
Bob is a team player, relationship builder, motivator, and people person who interacts well with all levels of the organization. He has an excellent knowledge of statistics and has experience teaching DOE’s, SPC, Hypothesis Testing, etc. Bob’s unique style of learning, then applying, lends itself to rapid and sustainable improvement. Bob has facilitated numerous, successful kaizen events involving cross functional and cross level participants.
Bob’s educational background includes a BS degree from the University of Rochester with a double major in Physics and Math. Bob is a Six Sigma Black Belt and has experience leading multi-plant Six Sigma implementations.
close biographyMr. Byron Stansfield is an Associate of The ACCESS Group with over twenty five years of experience in engineering, quality assurance and leadership positions. Byron’s work experience includes full time and consulting positions in various industries including construction, chemical, textile, and professional service and automotive. Byron has held positions as a process engineer, lead auditor, director of quality, management representative and regional operations director. Byron has worked with organizations such as DuPont, Cummins, Mercedes-Benz, Mitsubishi and The University of Tennessee.
Byron has lead many projects including the overhaul of intermediate chemical plants, computer programming and international production line expansion. Byron has also helped to streamline documentation and improve effectiveness of quality management system performance for large multi site companies and international organizations. Byron’s skills include the ability to work with all levels of an organization to drive improvements. Byron has also done business planning, marketing development and led an organization to achieve 20% sales growth and number 1 market share. Also, Byron received an environmental award for reducing waste by $400,000/year. Byron had developed and implemented efficient workshop based training courses in management systems and lean manufacturing. Byron has been a speaker at industry training conferences and manufacturing extension partnerships seminars.
Byron has a Batchelor of Science Degree from West Virginia University. Byron is an ISO/TS 16949 International Qualified Auditor per the International Automotive Task Force and a Lead Auditor per the RABQSA. He is a Certified Quality Engineer per the American Society of Quality. Byron has also completed extensive training in lean manufacturing principles and lean supply chain logistics.
close biographyMatt Stewart is an Associate of The ACCESS Group (TAG) and has over seventeen years of experience in operational and leadership positions. His operational experience includes extensive involvement in lean manufacturing, plant management, materials management, program management, product engineering and quality system implementation for the complete value chain. Matt has held numerous positions within operational organizations from shop floor to senior management. Matt has worked in industries including automotive, heavy truck, machining, injection molding, assembly and others in both consulting and full time positions. Companies that Matt has worked with include ASC, Intier, JCI, Pilkington, World Gym, McNeilus Truck, Lear Corporation, Mexican Industries and others.
Matt has led many projects over his career ranging from a quality improvement system which was modeled by a major OEM for use in their own supply base to lean manufacturing conversions of plant wide operations in many different industries. Some of his accomplishments include leading a team through a total lean conversion at a light engine crankshaft manufacturing/assembly operation through reducing inventories (47 days to 5 days), floor space used (by 20%), total work force (by 24%) on same sales, cycle times and lead times. He also managed an implementation of a material pull system synchronized to the customer demand that level schedule for the whole production floor resulting in the reduction of 93% missed shipments, a 47% reduction in excess unneeded finished goods, an overall improvement in BOM accuracy from 41.2% to 92.7%, and a reduction in hourly overtime of 74%.
Matt interacts well with people from all levels of the organization, which has been instrumental in the successful projects he has led. Matt’s involvement in the value stream includes all facets including lean plant layouts, employee training, plan implementation, performance measurements, and ongoing operations. He is intimately familiar with JIT and sequencing for the automotive industry, pull and kanban systems, cellular and single piece flow manufacturing processes, level loading, and other lean manufacturing principles. Matt is an enthusiastic leader that gets results by involving and teaching the people he works with in order to ensure success both during the implementation and after his engagement is complete.
Matt’s educational background includes a Bachelor of Science Degree in Chemical Engineering from Michigan Technological University. He has received Certification in Lean Manufacturing and Six Sigma Methodology – Black and Green Belt from University of Michigan-College of Engineering.
close biographyMr. Robert Stapp is an Associate of The ACCESS Group with over sixteen years of experience in various industries including automotive, mining, glass manufacturing, vocational truck, and publishing. Robert has held positions as a Front Line Supervisor, Manufacturing Manager, Business Unit Manager, and CI Division Manager for North American Operations, as well as, having served in many project management roles in the world of continuous improvement. Robert has worked with companies such as Pilkington, Hendrickson International, UNG, Hayes Lemmerz International, Household Products, and Maytag.
Robert possesses strong analytical and business assessment skills, which are firmly grounded in Six Sigma & Lean Manufacturing. Robert began his career as a front line supervisor under the direction of a Japanese management team, which taught and nurtured the foundational skills of the Toyota Production System. During his tenure, he has become well versed in applying the most elite process improvement methods in service and manufacturing. His background includes Kaizen Blitz methods, Six Sigma DMAIC, Theory of Constraints, and Lean Manufacturing. Robert has been involved in large-scale plant modifications and start-ups. He has experience in field engineering projects, strategic business assessments and continuous improvement implementation. Robert has excellent cognitive, interpersonal and teaming skills. He is a seasoned professional who portrays both hands-on and leadership characteristics at all levels of an organization.
Robert attended the University of Kentucky, College of Arts and Sciences, graduating with a degree in Psychology. He is a certified kaizen instructor and problem solving expert. Robert is also a certified Six Sigma Black Belt and Lean Master. Robert has recently served on the Board of Directors for HCL, a non-profit organization, which teaches Leadership Development and Project Management. Robert was awarded the Scott P. Faurote award for outstanding contribution to the academy during his service on the board.
close biographyBefore joining TAG, Tom served as President of Transformation Group, Inc,. Tom Stoffel developed TGI Healing Healthcare – a brand of Lean Healthcare training tools designed to make lasting improvements. With over 10 years of continuous improvement experience, Tom has helped hundreds of organizations make lasting improvements. He has developed an excellent working knowledge of Lean practices and principles by working with a diverse client base - Fortune 100 companies down to less than 15-employee manufacturers. In the healthcare environment, Tom has led healthcare organizations in both the development of high-level Lean Strategies down to hands-on implementation of Lean in a clinical setting.
Tom has achieved the levels of Certified Lean Specialist from the Business Improvement Group and the National Institute of Standards and Technology (NIST), along with being an ASQ Certified Quality Engineer. These certifications build on an Engineering Degree from the University of Michigan. Training experience includes Lean, Quality, and Leadership Training, as well as serving as an Adjunct Faculty Member at Waubonsee Community College.
close biographyMr. Clell Tompkins is an Associate of The ACCESS Group with over 38 years of experience in various industries including plastics, woodworking, painting, silk screening, electronics, assembly, extrusion, injection molding, hot stamping, thermoforming, and tooling. Clell’s operations experience includes extensive leadership roles in manufacturing operations and processes, quality systems including ISO, materials, supply chain logistics, engineering, purchasing, HR functions, concurrent engineering from product design to customer, management and supervision training, and plant relocations & startups. He has held positions as industrial insurance risk engineer; industrial engineer; manufacturing engineer; manager of quality assurance; production manager; plant manager; operations manager; and director of operations. Clell has also served in a number of project rolls such as plant shutdowns, feasibility studies, design of lean manufacturing concepts for new operations, overseeing the renovation for new startup facilities, plant and process moves, hiring and training of staff for new locations, and new production startups. Companies Clell has worked with include Telex Communication, Aladdin Industries, Gibson Guitar, Phillips Consumer Electronics, Magnavox, Industrial Risk Insurance Company and others.
Clell has enjoyed great success in executive positions as leader, teacher, trainer, and hands on supporter for empowering managers, workforces, and work teams taking them to a level of success they never thought possible. This was accomplished through lean principles, employee involvement, learning how to trust, good communication, continuous improvement, an error free environment by doing it right the first time every time, lean organizations, and systems skills. These successes were accomplished using lean tools such as value stream documentation, 5S, work cells, one piece flow, and many other ways of eliminating duplication, bottle necks, errors, and waste. Clell’s knowledge, experience, teaching, and hands-on approach using employee involvement and empowerment enabled others to accomplish major reductions in labor content, reductions in labor turnover from 80% to less than 5%, inventory turns from less than 1 turn to 10 turns in a short time, cycle time reductions from weeks to days, excellent customer service and relations, development of strong teams, and employee satisfaction. He not only teaches and trains workforce empowerment but has the ability to connect with people in all parts of organizations to guide and show them how to accomplish much more through the concept of lean.
Clell has a BS in Industrial Technology from Tennessee Technological University; completed studies and training from the Conway Management Company in continuous improvement and lean concepts; Continuous Improvement Process from Mark IV Industries certified as champion, trainer, and facilitator; Telex Company management and supervision training; Kepner Trego Problem Solving and Decision Analysis Techniques; Value Engineering from East TN State; Concurrent Engineering / Taquchi Methods (Certificate from Western Michigan Univ.); safety training from TOSHA; Overview Training in 6 sigma and Techniques of reducing cost and eliminating waste.
close biographyBob Trainor is an Associate of The ACCESS Group (TAG) and has over thirty-six years of experience in operational and leadership positions. His operational experience includes extensive involvement in manufacturing, warehousing and distribution operations, lean manufacturing, process improvement, training and coaching employees, facility layouts, facility relocations and business planning. Bob has held numerous positions within operational organizations from shop floor management to executive staff support level. Bob has worked in industries including food processing and packaging, metal forming and fabrication, machining, plastic injection molding, remanufacturing, wood products manufacturing, and others in both consulting and full time positions. Companies that Bob has worked with include Kraft foods, Quaker Oats, Pepsi, J M Smuckers, Jordan Window, BestBilt Systems, Armstrong Floor Covering, Ingersoll Rand, Baxter Healthcare, Nike, Milwaukee Electric Tool, Technicolor and several others. Bob has taught Work Measurement courses at the University of Memphis both at the undergraduate and graduate levels.
Bob has led many projects over his career ranging from new facility layouts to facility relocations and implementation of lean manufacturing conversions of plant wide operations in many different industries. Some of his accomplishments include helping companies improve work processes to better meet customer needs, reduce waste and increase profits and throughput. He also was a member of a facility relocation team for a plant consolidation project for a supplier in the automotive and truck parts aftermarket. Bob has implemented several warehouse and distribution center improvement projects to increase productivity, storage capacity and throughput. Bob has been involved in several automation projects in operations where the payback has been in a very short time period.
Bob interacts well with people from all levels of the organization, which has been instrumental in the successful projects he has led. Bob’s involvement in the value stream includes all facets including business plan development, lean plant layouts, employee training and coaching, plan development and implementation, performance measurements, and follow up. He is very familiar with problem solving, operations analysis and work task sequencing for reducing cycle times and increasing productivity, single piece flow manufacturing processes, level loading, and other lean manufacturing principles. Bob is an enthusiastic leader that gets results by training and coaching the people as well as involving the people in the change process. Bob works to make sure that process improvements stay long after implementation.
Bob’s educational background includes a BS degree from Clemson University in Clemson, SC and holds an MBA from Southern Illinois University in Edwardsville, IL .Bob is a member of the Institute of Industrial Engineers where he is e President of the Memphis, TN chapter and a member of The Society of Manufacturing Engineers.
close biographyRichard Tucker is an associate of The ACCESS Group (TAG) with over sixteen years of business and industry experience in operational and leadership positions. His experience includes new program installation and launch, operations improvement, lean manufacturing implementation (internally and with suppliers), leadership development and supplier program management from prototyping through launch. Richard’s experience as Manager of Technical Purchasing has given him a good understanding of major cost drivers and how lean tools can be utilized to make short and long-term impacts to a company’s bottom line. Richard has extensive intercultural experience working with Japanese and German counterparts at the OEM and Tier 1 level including Nissan, Bridgestone/ Firestone, Robert Bosch and General Motors Powertrain.
Richard has led many projects over his career ranging from development and transfer of equipment sourced in Japan to coaching supplier leadership in results-oriented lean implantation. His accomplishments include leading the installation and startup of Nissan’s Intelligent Body Assembly System (featured in Ward’s Auto World and Automotive Design and Production magazines). He has led the implementation of an operations level policy deployment model to focus resources on high-leverage projects to improve productivity and quality at a major Tier 1 supplier plant. Richard utilized Shainin Statistical Engineering Techniques to resolve failures on shaft insert station and improve throughput 13%. He has applied lean tools and methods such as OEE and root cause analysis to reduce scrap and improve productivity to eliminate $335k/year of unplanned overtime.
Richard has experience working at multiple levels within an organization from the shop floor to the boardroom and seeks to train, coach and develop others to understand the philosophy behind lean techniques. An experienced facilitator, Richard has lead workshops to identify and implement specific cost reductions on current production as well as capital equipment reduction and design optimization on products in the pre-production phase. He has lead Design For Manufacturability workshops to reduce capital expenditures. ($140k capital and $30k customer owned tooling on GM LS3 IAFM program), and Supplier Lean Production workshops to reduce labor content and quality costs ($189k/year labor reduction and $50k/year cost-of-quality on DCX PCHC program). He has utilized his experience to analyze manufacturing feasibility of design alternatives during design and prototyping phase. (i.e. ad hoc DFM activities) and negotiate pricing based on process cost drivers versus supplier quotes. (Major savings over program life: Hydraulic Block $8.9M, RWD PSM $1.0M, FWD PSM $1.1M)
Richard’s educational background includes BS and MS degrees from Tennessee Technological University in Cookeville, Tennessee. Richard has attended formal training courses in the Toyota Production System, Lean Manufacturing, Shainin Statistical Engineering and is certified by FranklinCovery to facilitate 7 Habits of Highly Effective People and Principle-Centered Leadership workshops.
close biographyMr. Terry Veazey is an Associate of The ACCESS Group with over fifteen years of experience primarily with automotive first and second tier suppliers and having peripheral experience in computer assembly and engineered construction components. His varied experience has exposed him to processes such as metal working, metal forming, welding, manual assembly, injection molding, gauging, process and layout design, and process documentation. Terry began his career as a manufacturing engineer with United Technologies. He then transferred that experience and mechanical aptitude to the quality field, beginning with Met-com as Quality Manager, creating for them an ISO compliant quality system. He oversaw domestic and European certifications for tempered and laminated vehicle and construction glass product at Nashville Tempered Glass. Terry also served a Supplier Quality Engineer in the General Motors Shreveport Assembly plant during the transition from the S10 to the 2005 Colorado models. Most recently he was involved as a Quality Engineer in the greenfield startup of a satellite tier 1 plant to supply Nissan Smyrna.
As quality engineer Terry is able to implement the accepted quality tools of problem solving and problem reporting including 8D. He has implemented SPC in assembly and machining operations and developed the gauging tools for this implementation. In various roles it has been his charge to create for submittal PFMEA, control plans, gauge R&R reports, dimensional layouts, APQP, and PPAP submittals. He has also been responsible for acceptance review of similar material from vendor companies. Terry has provided quality engineering support for several process startups and multiple product launches. He is comfortable with the production floor level personnel and has directed and trained inspectors and process operators in union and non-union environments. Terry is an accomplished user of AutoCad2000 2D graphics and similar graphics applications, MINITAB 13 statistical software, Microsoft Office and other Windows applications.
Terry is a graduate of Memphis State University with a degree in Engineering Technology. He has benefited from employer sponsored continuing education including the following:
Brian Weisfeld is an Associate of The ACCESS Group with over twenty–five years of experience in various industries including manufacturing and distribution. Brian has held positions as a methods engineer and senior manufacturing engineer, as well as, managing various plant upgrade projects. Brian has worked for companies such as Milwaukee Electric Tools and Dow Corning Wright. He has consulted with companies that include Baxter Health Care, Hamilton Beach Proctor Silex, Thomas and Betts and JM Smuckers and others.
Brian possesses strong industrial engineering skills having consulted in various process improvement projects with over 90 companies in the areas of manufacturing, distribution and warehousing. He has worked on projects involving performance measurements, cellular and lean manufacturing and employee training. He has extensive experience in AutoCAD LT 2006 involving plant and distribution center warehouse layouts.
Brian attended the University of Memphis with a B.S. in Manufacturing Engineering Technol