Introduction
John has over thirty years’ experience in engineering, manufacturing and business management at all levels. John has held manager and director level positions in mid to large size manufacturing companies (such as Black & Decker) as well as initiating his own startup manufacturing corporation. Since selling his ownership in that company, he has devoted his time to assisting a variety of companies in improving their business and manufacturing operations. His industry experience includes a developed expertise in leadership in the design, testing/development, manufacture, and quality assurance of gasoline and electric motors and their related products and vehicles. |
Profile
John’s expertise is in building lean manufacturing, just-in-time, build-to-forecast and build-to-order organizations. He is experienced with providing service to all levels of distribution; wholesale, dealer, retail, mass merchandising, catalog and tier 1 OEM. He drives growth and profitability through operational and financial excellence and improves quality and reduces costs through process and system re-engineering.
In 1987 John started BST Enterprises, a manufacturer of motorcycle accessories and averaged 28% annual growth before selling his interest in the firm in 2004 at an optimal time. He introduced lean manufacturing and Six Sigma techniques into the organization and succeeded in becoming a tier 1, JIT supplier with excellent quality and delivery to a new Harley Davidson factory
Since 2004, John has specialized in building high performance and cross-cultural teams for multiple organizations.
Key Skills: Quickly grasps and solves complex problems. Hands-on leader that motivates others to action. Wins confidence from all levels. Action oriented, gets things done quickly. Blends operations expertise with strong communications skills. Facilitates change management through open communication. Change agent.
Representative Work Experience
Automotive, Powersports
Designed and implemented (including personnel training) single-piece flow and lean manufacturing with controlled product cost and inventory reduction using a Hispanic workforce for a motorcycle and snowmobile accessory manufacturer, which resulted in a 10% increase in cash flow. Included in this effort was an efficient consolidation of a second facility. Developed sources and moved manufacturing for low-margin products off shore to reduce costs 20% with an improvement in quality.
As Interim GM for a $3M motorcycle windscreen manufacturer, reengineered processes for lean manufacturing. Redesigned supply chain and workflow to reduce work-in-process 90%, improve on-time delivery 20% and reduce inventory-on-hand 30%
Developed a new product process flow and quality methodology for metal stamping/forming and assembly operations for a $14M automotive parts manufacturer.
Directed product design for OEM alloy automotive wheels for multi-plant manufacture. Consistently met and exceeded major automakers' specifications for quality and delivery. Achieved Ford Q1 supplier rating.
Led engineering of automotive aftermarket division of multi-plant operation which included design, testing, manufacturing and importing of various accessories
Developed product component designs for moped project, consistent with adaptability to manufacturing equipment and efficiency of tooling and workflow on high volume equipment. Directed laboratory performance / endurance testing and regulatory compliance evaluations.
Electronics
Provided lean workflow layouts to manufacturer of electronic measurement components that resulted in major efficiency gains and reductions in lead times.
Gas/Electric Products
Developed products of high manufacturability and led projects (concept through production) for major manufacturers and importers of gasoline, diesel and electric-powered consumer/professional outdoor power products.
Directed testing for compliance to industry regulated and voluntary performance and safety standards, domestically and internationally.
Sports Equipment
Assisted project team of $80M fitness equipment manufacturer in establishing lean, single piece flow production line for company’s new design elliptical trainer.
Food Manufacturing
Implemented techniques of lean manufacturing to double capacity and increase efficiency of production (central kitchen) of $60M privately held fast food company to position it for planned rapid growth.
Restructured inventory control systems to streamline purchasing and data entry systems after introducing an upgraded ERP system.
Improved process flow and work scheduling for a meat and sandwich packaging facility specializing in distribution to prisons and schools.
Client and Company Listing (partial)
Homelite-Textron
McCulloch-Black & Decker
Superior Industries, Inc.
BST Enterprises, Inc.
Zero Gravity Inc.
Star Trac, Inc.
American Coil
Border Foods
Harvest Farms
Endevco Corp
King Taco, Inc.
Charles Abbot Associates
Intelligent Optical Systems, Inc.
California Waste Services
Advanced Manufacturing Group
Education
Rensselear Polytechnic Institute-M.S. Management
Rensselaer Polytechnic Institute-B.S. Mechanical Engineering
John’s expertise is in building lean manufacturing, just-in-time, build-to-forecast and build-to-order organizations. He is experienced with providing service to all levels of distribution; wholesale, dealer, retail, mass merchandising, catalog and tier 1 OEM. He drives growth and profitability through operational and financial excellence and improves quality and reduces costs through process and system re-engineering.
In 1987 John started BST Enterprises, a manufacturer of motorcycle accessories and averaged 28% annual growth before selling his interest in the firm in 2004 at an optimal time. He introduced lean manufacturing and Six Sigma techniques into the organization and succeeded in becoming a tier 1, JIT supplier with excellent quality and delivery to a new Harley Davidson factory
Since 2004, John has specialized in building high performance and cross-cultural teams for multiple organizations.
Key Skills: Quickly grasps and solves complex problems. Hands-on leader that motivates others to action. Wins confidence from all levels. Action oriented, gets things done quickly. Blends operations expertise with strong communications skills. Facilitates change management through open communication. Change agent.
Representative Work Experience
Automotive, Powersports
Designed and implemented (including personnel training) single-piece flow and lean manufacturing with controlled product cost and inventory reduction using a Hispanic workforce for a motorcycle and snowmobile accessory manufacturer, which resulted in a 10% increase in cash flow. Included in this effort was an efficient consolidation of a second facility. Developed sources and moved manufacturing for low-margin products off shore to reduce costs 20% with an improvement in quality.
As Interim GM for a $3M motorcycle windscreen manufacturer, reengineered processes for lean manufacturing. Redesigned supply chain and workflow to reduce work-in-process 90%, improve on-time delivery 20% and reduce inventory-on-hand 30%
Developed a new product process flow and quality methodology for metal stamping/forming and assembly operations for a $14M automotive parts manufacturer.
Directed product design for OEM alloy automotive wheels for multi-plant manufacture. Consistently met and exceeded major automakers' specifications for quality and delivery. Achieved Ford Q1 supplier rating.
Led engineering of automotive aftermarket division of multi-plant operation which included design, testing, manufacturing and importing of various accessories
Developed product component designs for moped project, consistent with adaptability to manufacturing equipment and efficiency of tooling and workflow on high volume equipment. Directed laboratory performance / endurance testing and regulatory compliance evaluations.
Electronics
Provided lean workflow layouts to manufacturer of electronic measurement components that resulted in major efficiency gains and reductions in lead times.
Gas/Electric Products
Developed products of high manufacturability and led projects (concept through production) for major manufacturers and importers of gasoline, diesel and electric-powered consumer/professional outdoor power products.
Directed testing for compliance to industry regulated and voluntary performance and safety standards, domestically and internationally.
Sports Equipment
Assisted project team of $80M fitness equipment manufacturer in establishing lean, single piece flow production line for company’s new design elliptical trainer.
Food Manufacturing
Implemented techniques of lean manufacturing to double capacity and increase efficiency of production (central kitchen) of $60M privately held fast food company to position it for planned rapid growth.
Restructured inventory control systems to streamline purchasing and data entry systems after introducing an upgraded ERP system.
Improved process flow and work scheduling for a meat and sandwich packaging facility specializing in distribution to prisons and schools.
Client and Company Listing (partial)
Homelite-Textron
McCulloch-Black & Decker
Superior Industries, Inc.
BST Enterprises, Inc.
Zero Gravity Inc.
Star Trac, Inc.
American Coil
Border Foods
Harvest Farms
Endevco Corp
King Taco, Inc.
Charles Abbot Associates
Intelligent Optical Systems, Inc.
California Waste Services
Advanced Manufacturing Group
Education
Rensselear Polytechnic Institute-M.S. Management
Rensselaer Polytechnic Institute-B.S. Mechanical Engineering