Developed and implemented manufacturing strategy for electronic instrument manufacturer. New process control methodologies were introduced in machining, sheet metal fabrication, thick-film hybrid circuit manufacturing, and board assembly. Overall electronic test yield improved from average of 68% to 97% within three-month period.
Developed manufacturing strategy for producer of mid-range memory boards and SIMM modules. Manufacturing strategy focused on both a cost-reduction restructuring for memory products and new business unit for packaged network products. Effort began with executive workshops to frame business strategy prior to manufacturing strategy development.
Developed and implemented Cycle Time Reduction strategy for semiconductor equipment manufacturer. Managed joint Client/consulting team to reduce equipment quotation/manufacturing/delivery cycle by 50%. Success of project was featured in 1991 issue of Electronic Business.
Managed systems analyses for large-scale distribution terminal. This unique “flow through” design serves as the “Just-in-Time” hub for a major automotive assembly plant. Detailed simulation modeling of proposed design analyzed all aspects of both operations and computer control systems.
Managed systems analysis of one of worlds largest automation systems for major automotive manufacturer. Design focused on selection of parallel, modular, assembly areas for subassembly installation utilizing over 1,000 automated guided vehicles (largest AGVS design in the world at the time).
Managed systems engineering of large-scale material handling system for major automotive components. System design included AGVS, Electrified Monorail System, inverted Power-n-Free and 1500 bin location AS/RS with daily turn of 6. Both scheduling and material handling control algorithms were developed for this system which is considered the benchmark for similar systems worldwide and has been featured in Manufacturing Engineering and Material Handling.
Principal developer of group technology technique termed OPSNET as part of a new facility design for aerospace gas turbine engine manufacturer. New technique allowed over 1,100 turbine engine parts to be classified in fraction of time required by conventional techniques. This method has been used across other Department of Defense facilities and is now used by a major consulting firm.
Managed concept and design of advanced sheet metal blanking and bending fabrication system for U.S. Air Force ICAM Program. As part of systems analysis, one of first aerospace simulation/optimization (integer programming) models was developed.
Performed manufacturing systems design analysis on one of world’s largest transmission manufacturing facilities. Over $125 million in dial and transfer machining systems and asynchronous material handling equipment was involved. Over $12 million in capital cost avoidance was identified through dynamic analysis of plant material flow.