Senior Industrial Engineer Expert Witness

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Senior Industrial Engineer Expert Witness

Provides Opinion & Testimony In:

Engineer, Engineer Industrial, Tire Manufacturing, viability of new equipment, manufacturing processes, cost justifications amortization rates, tire presses, curing room, equipment maintenance, Tires, vulcanization, timestudy, work methods, ROI calculation, standards, MTM, MOST, methods time management, allowance, justifications, curing equipment, daywork standards, piecework, incentive system, AutoCAD, equipment layout, kanban, COIN inventory system, JIT, standard cost, ergonomics, predetermined time systems, facilities planning, production planning, master scheduling, inventory control, work simplification, stopwatch studies, work sampling, grievances, union, Mitsubishi, Akron Standard, SRI, NRM, 88C, 88B, tire building machine, uniformity machine, TUO, balance machine, bulge dent machine, buffing machine, fabric Calendar, steel creel Calendar, innerliner, body ply, chafer, cap ply, NEB, JLB, PR760, PR730, NRM110, Bartell 2000, dynamic balancer, cost reduction, labor efficiency, job descriptions, autoclave, two piece mold, segmental mold, dry ice blasting, tire conveyor systems, FIFO, downtime, banbury, palletizing, monoply,First In First Out, National Standard Tires

Expert Witness No.1397


Senior Industrial Engineer:  Effective in utilization of resources, process improvement, increasing productivity and reducing costs. Experienced in time study analysis, establishing daywork and piecework standards, team building, training and production scheduling.  Functioned in an ISO 9001:2002, ISO 14001, QS 9000 and TS 16949 certified manufacturing facility.

Major Accomplishments

Co-authored and introduced computerized equipment capacity spreadsheet as the active management tool for resource planning including scenario evaluation for schedule fluctuation and product mix variation.

Selected for training at several Goodyear factories in Germany in 2000 to analyze optimal equipment capacity of the Huntsville factory via a universally standardized Capacity vs. Potential analysis tool.

Successfully identified, by acquisition of data taken during a two week audit, each primary producing process in the factory and determined what capital expenditures were necessary to enhance the output of each operation to achieve an overall 12% factory output improvement.

Applied MOST (computerized keyword recognition software) time study technique to all phases of the tire building operation for a major overhaul of the incentive rate system.  Results tallied as much as 48% productivity gains in output for second stage tire building and annualized savings of US $ 2.7 million.

Successfully implemented a high tech equipment and material handling module providing overall improvements in reduction of operatives, increased productivity and a quality assurance process suited for O.E. (Original Equipment) processing resulting in an annualized savings of US $ 1.2 million.

Professional Experience

A Retread Manufacturing Facility located in Georgia – 2003 to Present

Independent Contractor Industrial Engineer
Employed on a part time basis to analyze processes and manning opportunities using job restructuring for efficiency gains.  Specific improvements include:

Identified bottlenecks in key supply chain operations and instituted manning changes enabling production leveling

Instituted bonus system in Unicircle curing operation as pilot for implementing in subsequent processes throughout the factory

Assessed ergonomic issues and followed up with automation improvements with reel windup for tread, vacuum hoist lifting devices and dual extrusion for greater capacity

Coordinated efforts for the “Social Circle Lean Manufacturing Imperative” with specific manning reductions/combinations totaling 25 operators for approximately US $1 million annually

Concentrated manning restructuring around Lead Man concept for improved communications and transferred crew responsibility for day to day operation

Goodyear/Dunlop Tires North America LTD., Huntsville, AL   1985 – 2003
The Dunlop Original Equipment Tire Facility

Senior Industrial Engineer

Full responsibility for Business Center manpower efficiency, daywork standards and equipment layout improvements in the Curing, Finishing and Warehouse departments.

Conducted cost feasibility studies and justifications for capital projects with added capability of design rendered via AutoCAD 2000.

Provided hard copy plant facility layout proposals, including both categories of new equipment installation drawings as well as existing equipment modifications supporting automation and efficiency improvement projects.

Satellite responsibilities:   Liaison to Japanese advisory staff for the implementation of FIFO inventory control systems for Green Tire storage; supplier of primary plant visual aids utilizing AutoCAD, Corel Draw and Print Artist software packages.

Key Assignments:

Efficiency / Manning reduction – Industrial Engineer coordinator at Huntsville plant for Nashville Manning Analysis & Discovery Workshop – resulted in capital expenditure approval for projects to eliminate 37 employees/staff members.  Nashville, TN

Efficiency – Apply NEP (new efficiency process) European origin to US plants at both Huntsville, Alabama and Freeport, Illinois.  Furstenwalde and Hanau, Germany
Equipment Automation /Manning reduction – Research total scope of automated final finish module and design equipment routing for elimination of redundant manual processes.  Huntsville, AL
Computerized Inventory management – Determine applicability of Japanese tire room inventory system to US curing and finishing operations ( implementation effective in curing and tread production processes).  Kobe, Nagoya and Shirakawa, Japan

Manning reduction – Emulate existing OE finishing module at Amiens factory to Huntsville plant.  Amiens, France

Dunlop Tire Corporation, Huntsville, Al    1977 – 1985

Manager Resource Utilization

Assigned as coordinator between Engineering, Production and Technical for major cost reduction projects.

Achieved completion of projects to increase tire component package size at extrusion and fabric cutting which represented significant labor and scrap reductions in the tire building phase.

Other diversified assignments included responsibility for quarterly audit of appropriations and assisting as backup Master Scheduler for radial tire building.
Master Planner Supervisor
Promoted to salary ranks with responsibility for master scheduling of the dual stage tire building process with coordination of machine changeovers and supervision of component schedulers on several shifts.
Shift Scheduler
Provided entire plant scheduling functions on second shift, including daily tire component inventories and routine schedule adjustments.

Education and Training

BS Geology – University of Missouri at Kansas City
Methods Time Management (MTM 1) Certificate of Proficiency
Certified MOST (Maynard Operational Sequence Technique) Computer System Applicator
Internal Auditor ISO 14001 Training
Advanced Materials Requirements Planning
XCell Factory Modeling Simulation
Automated Material Handling and Storage Systems
Dynamics of Supervision
Inventory Management
Quality Circle Leader Training Course
Excellence through Teamwork
Occupational Ergonomics – Auburn Engineering

Currently enrolled at Calhoun Community College in the
pursuit of an Associates degree in Computer Graphics / Digital Imaging