Summary
Overview
Work History
Education
Skills
Affiliations
Timeline
Generic

Andrew Bird

Asheville,NC

Summary

Lean Engineer with varying experiences in multiple manufacturing industries with a strong background in lean methodology, kaizen improvements, Six Sigma methodology & process improvement.

Overview

8
8
years of professional experience

Work History

SF Transformation Engineer/Novecare Referent/PMO

Syensqo
Alpharetta, GA
06.2023 - Current
  • Guided creation of Star Factory roadmaps for six NAM sites within Novecare.
  • Led and coordinated internal team members to ensure that APAC and EMEA zone sites (6) delivered the creation of their roadmaps on time.
  • Led and participated in GMO and AA/APC diagnostics, identifying over $5 million in total potential.
  • Marietta CBM implementation using PI AF (ongoing).
  • PMO responsibilities include Wave system updates, Star Factory governance playbook management, and program-level sustainability tracking changes.
  • Optimized the existing ELT industrial pipeline reporting and data architecture, utilizing Google Sheets and Wave extractions.
  • Developed, with additional team members, C&R level SteerCo data architecture and report out.
  • Trained globally multiple sites within different GBUs on Star Factory governance best practices and Wave usage.
  • Performed maintenance Bad Actor analyses for varying sites and GBUs on an as-needed basis. ($250k+ potential identifed among all analyses)
  • Worked on a team to align the Wave financial reporting structure with the C&R Finance reporting structure (ongoing).
  • Led multiple site 'Vision Workshops,' defining the site vision out to 2030.

LEAN Engineer/Tremec Core Team Leader

Linamar
Arden, NC
11.2022 - 03.2023
  • Developed and implemented a plant wide 5S program.
  • Trained leadership team members on lean fundamentals site wide.
  • Formed a campus LEAN team to document best practices, develop FY23 LEAN roadmap, standardize PIM, focus on employee engagement & quality of life.
  • Implemented hand documented lean suggestion program to drive employee engagement. Monthly savings from plant floor employees rose from $1k - $8k.
  • Coordinated and led a cross functional team of 10 engineers (quality & manufacturing), supervisors, and material coordinators to own and drive improvement in KPI's on Tremec line.
  • Developed PM schedule and standard problem solving approach to leak tester issues to minimize downtime and stabilize daily throughput from varying between 120pcs-200pcs to 190pcs-210pcs.
  • Created new MRB flow to allow rework parts to be introduced back into the process quicker after disposition, as well as cut MRB time from 3 hours daily to 1 hour daily.
  • Assisted in creating data capturing structure to allow for further analysis of gross leakers, and impreg parts narrowed down to machine path, die #, and cast date to address quality problems quicker and more efficiently.
  • Worked with supplier to implement quality checks and process improvements to decrease supplier related quality issues found at our final inspection resulting in increase of FI FTY from 65% to 90%.
  • Coordinated with customers concerning quality escapes, 8D status, and proven out resolution to the initial issues causing the quality concern.
  • Reimplemented visual andon lights to alert team of machine issues causing downtime, when a machine is starved due to upstream processes. Decreasing maintenance response time and increasing operations rate from 5.5 JPH to 7.8 JPH/OP.
  • Developed check & balance system for chip house to ensure that chip bins were not being overfilled, coolant was properly draining out, and documentation was in place to prove we were complying with OSHA & state regulations.
  • Performed FMEA's and Equipment Criticality Analysis through most criticial equipment through the site.
  • s

Continuous Improvement Analyst

TE Connectivity
Fairview, NC
02.2020 - 11.2022
  • Various VSM & D Kaizen Event Facilitation
  • Solenoid VST Leader, $3.1MM Last Time Buy to be finished production within 18 months
  • Plant Wide QCPC Implementation to improve productivity/efficiency while decreasing COPQ across the plant
  • Supply Chain Swimlane Process Flow Kaizen to create the Shortage War Room in order to better track & tackle part shortages inhibiting production
  • Digital 5S Zone Scoring System developed using Microsoft Forms
  • Digital Tier 3 KPI Tracking developed via Sharepoint & Power BI
  • A47 Output Overdrive Workshop - Designed labor layout to facilitate $800k of shipped product in 8 weeks. Facilitated a team to analyze current and future supply chain gaps in order to achieve future long term stability. Created & executed with a team & a plan to increase production rate from 81pcs/day to 130pcs/day. Integrated new metrics into PIM process to drive daily management.
  • F33 Output Overdrive Workshop - Designed labor layout to facilitate $1.6MM of shipped product in 8 weeks. Facilitated a team to analyze current and future supply chain gaps in order to achieve future long term stability. Created & executed with a team a plan to increase production rate from 300pcs/day to 803pcs/day. Integrated new metrics into PIM process to drive daily management.
  • D51 Output Overdrive Workshop - Designed labor layout to facilitate output of $2.1M in 13 weeks. Facilitated a team to analyze current and future supply chain gaps in order to achieve future long term stability. Created & executed with a team a plan to increase production rate from 300pcs/day to 658pcs/day. Integrated new metrics into PIM process to drive daily management.
  • Facilitated 3P Projects to move Solenoid Subs, Agastat Sub Room & GFI production line in the plant. Solenoid Sub move increased productivity & output, Agastat sub room move decreased space required by 50% as well as allowed for better flow of product, GFI product line move decreased space by 50% as well as the new layout was designed for better product flow.
  • CPG VST Leader - Increase production rate to 150pcs/day to burndown backlog & PDR in 6 months.
  • Z75 VST Leader - Facilitated RCCA's for various customer returns, facilitated DOE's to cut internal production cost & purchase turnkey parts, workstation design 3P.
  • Performed TEOA Onboarding for all new hires.
  • Facilitated rotational engineers redesign of CRG for implementation of one piece flow.
  • Co-facilitated Plant Wide Site Layout 3P Event

Project Manager/Engineer

Appalachian Antique Hardwoods LLC
Waynesville, NC
09.2018 - 01.2020
  • Estimated quantities and costs of materials, contract labor, to determine project feasibility
  • Created Standard Operating Procedures for multiple pieces of manufacturing production equipment
  • Performed process time studies to analyze efficiency, and determine process capabilities of manufacturing processes
  • Created an MRP system using data from process time studies, and yield studies
  • Assisted in the verification of standard costs for manufacturing processes
  • Performed incoming yield studies per vendor
  • 5S projects throughout the manufacturing facility
  • Performed construction take-off's for wood components in many projects/homes with total value of $1 million and up
  • Assisted in the coordination of shipping & logistics of orders
  • Assisted in walking clients through our various products and explained which would be best for their project specific needs
  • Worked on a new product development team to create, trial and market a new product line
  • Developed a Finished/Semi-Finished goods inventory system using Google Forms, Google Sheets, and QR Codes
  • Developed outbound shipment quality check system using Google Forms, Google Sheets and QR Codes

Technical Process Engineer

Shaw Industries Plant Z1
Franklin, NC
06.2017 - 08.2018
  • Worked with production managers, product category managers, and R&D to start launching a brand new product line
  • Worked on a team to increase a production lines square foot per hour from 1850- 2150 using six sigma principles
  • Automated production reporting, downtime reporting, and key performance indicator analytic charts
  • Created google databases for quality audits, production measurements, and start up procedures
  • Worked on a team to standardize machine specifications dependent on varying products
  • Worked on a team to decrease annual costs spent on belts by $15,000
  • Discovered communication errors between Production reporting systems, and Grading systems that decreased Plant Inventory Variance's by $25,000 while allowing for proper capturing of production data

Education

Bachelor of Science - Sustainable Materials & Technology

North Carolina State University
2017

Minor - Pulp & Paper Technology

North Carolina State University
2017

Skills

  • Google Sheets and Google Scripts (JavaScript)
  • Excel VBA
  • Minitab
  • JMP
  • Lean Six Sigma Green Belt
  • Microsoft Power BI
  • Kaizen Facilitation
  • 3P
  • 5S
  • VSM & Design
  • Microsoft Power Apps
  • 8D/PPSR
  • Hoshin Kanri X Matrix
  • Plant Goal Deployment
  • SEEQ
  • Extended Value Stream Mapping
  • Customer & Supplier Relations
  • ThinkReliability trained

Affiliations

  • Six Sigma Green Belt - Shaw Learning Academy
  • 7 Habits of Highly Effective People Training - Shaw Learning Academy
  • Keys to Communication - Shaw Learning Academy
  • How to have Crucial Conversations - Shaw Learning Academy
  • Professional Development Certification - NCSU LAUNCH Program
  • Campus Recruitment Trip - Shaw/NCSU

Timeline

SF Transformation Engineer/Novecare Referent/PMO

Syensqo
06.2023 - Current

LEAN Engineer/Tremec Core Team Leader

Linamar
11.2022 - 03.2023

Continuous Improvement Analyst

TE Connectivity
02.2020 - 11.2022

Project Manager/Engineer

Appalachian Antique Hardwoods LLC
09.2018 - 01.2020

Technical Process Engineer

Shaw Industries Plant Z1
06.2017 - 08.2018

Bachelor of Science - Sustainable Materials & Technology

North Carolina State University

Minor - Pulp & Paper Technology

North Carolina State University

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