Réal has over twenty-five years of experience in Operations, Operations Management, and Logistics. Réal has held positions including: Vice President of Operations, Director of Logistics, as well as Director of Lean Operations. His vast food manufacturing experience combined with an extensive Warehousing and Scheduling background all contribute to his unique skill set of cost reduction and lean implementation no matter what industry he serves.
Réal has expertise in implementing manufacturing systems, lean manufacturing tools and techniques, production control mechanisms, process improvement, change management, supplier quality management and quality systems. Starting as a Manufacturing Engineer and working his way through various Manufacturing Management positions, Réal has had the opportunity to design, facilitate, and implement lasting changes and improvement. Réal held various leadership positions, from VP of Operations, Quality Manager, Plant Manager. He coordinated two plant consolidations, managed a site of 100 workers, and lead product design teams. With over ten years in project management (as part of the White Goods Industry) and over eight years in the engineering consulting industries, Réal has proven time and time again that he can deliver projects of varying size and complexity on time and within budget to satisfied clients.
Representative Work Experience
Food Manufacturing (USA, Canada)
Led several implementations of multi-phase operational improvement projects for food manufacturers (frozen pizzas, pizza bites, egg rolls, school and airline meals, gelatin and pudding, yogurt, and candy). Key areas of focus where labor optimization, production throughput efficiency, scrap reduction, unplanned downtime reduction and development of operator training systems. Through the implementation of Lean Manufacturing tools such as line balancing, daily man loading matrix, visual factory tool and redesign of product stands, these projects resulted in yield of 152% improvement in labor efficiency, 1,000% reduction of over production, 27% improvement in maintenance crew response time. The several lean manufacturing projects in this industry resulted in saving of $1,000,000+/yr.
Worked in the construction of a new facility to consolidate two sites into one. Supervised the setup of the FG warehouse and stream lined the process of the candy making process.
Lean Business Assessment
Conducted several Lean Business Assessments (LBA) for manufacturing facilities in the metal transformation, thermoplastic and food industries. This involved establishing a baseline to evaluate the lean improvements, developing a lean vision for each production model, conducting a cost/benefits analysis, and creating a reasonable; results oriented detailed implementation plan based on the priority dictated from the analysis.
Stamping, Manufacturing, Printing and Assembly
Implementation of multi-phase operational improvement projects in the steel manufacturing industry, automotive, and consumer goods. Key areas of focus where productivity improvement, scrap reduction, line balancing, lead-time reduction, manufacturing cycle time reduction and on-time delivery. Through the implementation of Lean Manufacturing tools such as visual factory, production tracking, value steam mapping, and flow improvement. These projects had improvements between 25%-53% and ROI between 3 to 10.
Electronic Connector Manufacturing
Implementation of two multi-phase operational improvement projects for a manufacturer of electronic filter connectors. Key areas of focus were finished goods lead-time reduction, manufacturing cycle time reduction and on-time delivery. Through the implementation of Lean Manufacturing tools such as 5S, new manufacturing layouts and flow improvement, the project results yielded a 53.6% in travel, and manufacturing lead-time reduction of 25%.
Optimized a manufacturing area for an aerospace component manufacturer. The key areas of focus where manufacturing lead-time reduction, work place organization and development of work instructions. Through the implementation of Lean Manufacturing tools, the project results yielded a 47% reduction in space utilization, 76% in production lead-time and 32% in process cycle time.
Home Appliances (USA, Canada, France)
Executed and managed a $25 million dollar project for a new product design and launch. Implemented and managed equipment construction, installation and startup. This involved developing equipment specifications, conducting supplier cost/benefits analysis, and creating a reasonable; results oriented detailed implementation plan based on the priority dictated from the analysis. Focus areas during implementation included equipment construction management, factory layout and flow line development, parts management and point-of-use delivery, and co-located manufacturing support cells. The project implementation was achieved with a 10% under budget resulting in a $2,500,000 saving.
Bakery & Bakery Equipment Manufacturing (USA, France)
As an ImpleMentor, conducted a project in a gluten free bakery, with the use of Value Stream Mapping, developed improved production process flow that helped increase production by 5 times with the same crewing. Implemented and populated an ERP system for the bakery, developed and HACCP plan and supported the implementation of the new product costing model.
As Plant Manager and Product Engineering Manager for multi-million dollar manufacturer of industrial bakery equipment in France, Réal and his team implemented a plant consolidation of two sites in a single facility. Through redesign of process flow and work cell layout, the work force was optimized resulting in a 21% labor improvement and 15% lead-time reduction.
Client and Company Listing (partial)
Preferred Meal Systems
University of New Brunswick – B.S. in Mechanical Engineering
École Polytechnique – DESS (Master’s Degree) Engineering Project Management
Villanova University – Lean Six Sigma