Danny Weis
Nashville,Tn.
Summary
A challenging position in a Manufacturing, Engineering or Facilities Operational environment where my overall management and technical background, along with the leadership and decision-making capabilities, will be combined to render the most benefit to my employer.
I am a results-oriented business professional with experience in Manufacturing / Assembly / Quality environment, with proven abilities in strategic planning, managing projects, improving efficiency of operations, and team building. Strengths include: Leadership, Motivation, Communication, Development of Result-oriented organization (Implementation of company policies & standards, operational changes, optimization in productivity) Encouraging manager and analytical problem-solver with talents for team building, leading and motivating, as well as excellent customer relations aptitude and relationship-building skills. Proficient in using independent decision-making skills and sound judgment to positively impact company success. Dedicated to applying training, monitoring and morale-building abilities to enhance employee engagement and boost performance. Strong leader and problem-solver dedicated to streamlining operations to decrease costs and promote organizational efficiency. Uses independent decision-making skills and sound judgment to positively impact company success. Collaborative leader with dedication to partnering with coworkers to promote engaged, empowering work culture. Documented strengths in building and maintaining relationships with diverse range of stakeholders in dynamic, fast-paced settings. Talented Manager with expert team leadership, planning and organizational skills built during successful career. Smoothly equip employees to independently handle daily functions and meet customer needs. Diligent trainer and mentor with exceptional management abilities and results-driven approach. Insightful Manager with experience directing and improving operations through effective employee motivational strategies and strong policy enforcement. Proficient in best practices, market trends and regulatory requirements of industry operations. Talented leader with analytical approach to business planning and day-to-day problem-solving.
Overview
26
26
years of professional experience
1
1
Certification
Work History
Contract Sr. Industrial Engineer
ACTalent (General Motors, Springhill Assembly Plant)
10.2022 - 05.2024
- Virtual build 20205 Cadillac EV SUV
- All US models
- Set up Assembly process System for vehicle
- Line balance
- VS mapping
Contract Industrial Engineer
ACTalent (US Tobacco)
10.2021 - 06.2022
- Review machine applications
- Downtime
- Quality
- Reporting
- Member of Centerline team
- Value Stream Transformation of Cell A
- Improve line efficiency
- Work Instruction
- Management Reporting
- Maintenance Improvement
- Improve Downtime
Contract Lean Engineer
TWIG Products
01.2020 - 07.2020
- Develop and Implement Standard Work
- Teach Value Stream mapping
- Develop Visual Factory (Metrics, Hour by Hour boards, Value Stream Boards)
- Develop Kanban system (promote Flow, minimum inventory on floor, reduced forklift traffic, Improve Safety issues)
- Coach Kaizen events and participate in the lean transformation journey (Results included more efficient flow from warehouse through machine cells and out through packaging)
Contract Lean Engineer
Simpson Strong-Tie
11.2018 - 05.2019
- Develop and Implement Enterprise Lean manufacturing
- Coach, mentor and teach the principles of lean and how to reduce or eliminate waste in processes
- Established Cascaded metrics for the Branch, which included Value Stream metrics and cell level metric
- Coach Kaizen events (Results included 50% efficiency gain in packaging area, less truck traffic, inventory control)
- Coached through PFEP (Plan for every part) process in order to implement Kanban that would contribute to the reduction in inventory (30% reduction in floor level inventory)
Contract Lean Engineer
NTN bearing
01.2016 - 06.2018
- Implement Standard Work
- Teach Value Stream mapping
- Develop Visual Factory (Metrics)
- Develop and implement tooling area (flow, Standard work, Inventory control, reduction in setup times)
- Develop tooling coordinator role (Standard Work)
- Develop tooling cribs (Inventory control)
- Develop Kanban system for automotive manufacturing and assembly area (reduction in floor level inventory, flow of inventory, reduction of truck traffic)
- Coached Kaizen events (Results included ergonomically enhanced Assembly stands, 70% improvement in capacity and throughput)
CI Manager
Nelson Global Products
01.2014 - 01.2016
- Develop and Implement Visual Factory (metrics)
- Inventory reduction through Lean Manufacturing principles (Reduced / scrapped over 1 Million dollars in unusable inventory which also provided close to $150,000 a year in handling costs and floor usage costs savings)
- Reduced lead time of manufacturing processes (from 27 Days to less than 7 days)
- Instituted and drove the development of the Nelson Production System (Internal lean manufacturing)
- Implemented flow through the plant by moving machines in sequential order based on process, eliminated 80% of forklifts, and forklift traffic which contributed to a safer environment but also helped in driving only the right part, right quality, right time, and right qty
- Product carts were developed to move materials between processes.
Supplier Development
Caterpillar Global Purchasing
01.2010 - 01.2014
- Role was to assist suppliers to Caterpillar understand what their manufacturing issues were that contributed to poor shipping performance or quality problems, then help them using Lean manufacturing practices to become a better supplier.
- Project - Joliet Glass - Improved the quality of glass being delivered to the Caterpillar Joliet facility by hosting an RIW (Rapid Improvement Workshop / Kaizen)
- Event results were 30% improvement in material flow by changing Kitting floor layout (Staging areas, Shadow boards).
- Project -K&M Machine Fabrication (extended Value Stream project) – Total Cost of ownership.
- Reduction in costs as applies to total cost of ownership from raw material (casting suppliers through finished product at Caterpillar) Current Shipping performance is >98%, past dues = 0, ppm
- Dual Projects – Sustained Improvement
- Technical Metals in Fairbury, Ill – Improved Shipping performance from 45% to >89% (improved flow through facility, corrected transactional issues)
- Concentric – Rockford, Ill – Improved Shipping performance from 25% to >85% (trained employees on flow, corrected information flow through Production schedulers)
- Project - Advance Steel Technology in Rome, Ga
- Coached Supplier Management in VST / RIW methodology in the areas of QA, QA repair, Kit Build, and shipping area
- Project results; Supplier Shipping performance from 14% to 98%, and past due parts from 6000 pcs
- To 233 pcs
- Results accomplished via improvements in scheduling process, flow through facility, Inventory overproduction issues, storage location issues, and training.
- Project -Blue Diamond Cast, Michigan - Project was suspended after 6 weeks due to lack of supplier commitment and no internal resources.
- Project - NTN-Bower Bearing in Macomb, Ill – Coached Supplier project leader and CGN consultant in VST / RIW (8” Tapered Roller Bearing grind line and Assembly / Inspection)
- Completed area VST, 3 RIW’s
- Potential results after 6-month data maturity = > $6 million in benefits (labor, inventory, scrap, rework)
- Improvements in MRP scheduling, batch processing, scrap / rework process, gauging issues, and visual factory elements to drive improvements.
- Project - NTN-Bower Bearing in Macomb, Ill – Coached Supplier project leader in VST / RIW - ULT (Ultra Large Bearing) machine line
- Utilizing CPS tools, record high supplier past dues were reduced to 0, 20% improvement in Supplier Shipping Performance, 20% reduction in QCO times, and implemented Standard Work.
- Project - Metal craft of Mayville, Wisconsin – Coached Supplier project leader in VST / RIW Heat Shield area
- Project was completed with 0 past dues, 95% supplier Shipping Performance, Capacity Improvement 15%, Internal efficiency gains - 39 days’ lead time down to 5 days, QCO on line improvement from 59 min to 10 min, reduced part travel from >4000 ft to
Development Engineer
Caterpillar Production System
01.2006 - 01.2010
- Role was to be a part of the Caterpillar development team that would undertake the development of the Caterpillar Production Team
- This would be the future of Caterpillar as they moved to the next level in lean manufacturing.
- Project - Tech Center Building K - Safety RIW – Identify safety issues that led to increase in Recordable Injuries within plan
- Benefit to business unit = $108k
- 60 safety issues identified and resolved.
- Project - Tech Center, buildings TCK, TCG, TCL, PPG, TPG
- Deploy CPS methodology - Tools implemented include; Visual Factory (Metrics Cascade (hour by hour, area section, Facility Board)), CI, Standard Work
- 18% overall improvement in OEE / OEU
- (Overall Equipment Effectiveness, Overall Equipment Utilization).
- Project - MLS facility, Sanford, North Carolina - Deploy CPS methodology - Coached CPS Black Belt in project, utilizing CPS tools; benefits included a reduction in Urgent orders from BCP by 50 %
- Implemented Std
- Work, trained 12 CPS GB / YB
- Established process to schedule Trucks into dock
- Better control of inventory on floor.
- Project - Fargo, ND – Final Drive disassembly VST / RIW – Coached team towards $105k improvements
- Improved flow, 25 safety issues identified and resolved, and trained team in CPS GB / Yellow belt.
- Project - Franklin, Indiana – Coached CPS BB in engine assembly RIW
- Velocity through the assembly plant was improved by 50%.
- Project - Waco, Texas – CPS trained Waco team as CPS GB / YB plus for an upcoming RIW.
- Project - Jacksonville, Florida – Coached BB from the Work tools group (Bucket) for an RIW to improve flow in the plant
- Overall results were - 38% improvement in capacity, flow, and velocity.
- Project - Caterpillar Torque Converter, Summerville, SC – Coached Summerville BB through an RIW event
- Improved the assembly process by 50 %
- Implemented Std work.
- Project - Engine Test, Greenville, NC - Coached Greenville BB on project in the engine test area
- Results included - $177 K in engine scrap reduction, 50% improvement in throughput (new flow path, kitting / QCO), and $380k in cost reductions by establishing a process to capture and recycle fluids, reduction in overtime, WIP inventory.
- Project - Transmission Assembly / Test , Summerville, SC – VST training for team.
- Project - Perkins Engine Assembly Griffin, Georgia – Led VST / RIW project
- Train all employees in the Caterpillar Production System
- Result / benefits were from improving velocity through the assembly area, $1.2 mil in Value Prop
- Improved capacity of assembly area by 50%.
- Project - Caterpillar Reman , Corinth Mississippi – Was part of a team that did a complete Value Stream transformation of the reman facility
- All areas were covered with results in Culture through change Management, improved through put, Safety improvements, and quality improvements.
- Project - Backhoe boom fabrication line, Torreon, Mexico – Led a project team through a an RIW which Doubled production of backhoe loader booms
- The fabrication area was completely removed and reinstalled in 5 days
- Operators were trained, Standard work was implemented.
Operations Manager
Caterpillar Tractor
01.2005 - 09.2005
- Tasked with improving the Caterpillar Production System assessment score
- Completed that task by year-end
- Went from a 27 to greater than 46 points for both Corinth and Prentiss facilities
- The plant was over a year behind in its Caterpillar Production System Implementation
- By improving lean manufacturing practices, training employees, and implementing metrics the plant was able to meet Caterpillar Production System implementation goals
Development Engineer
Caterpillar Tractor
01.2000 - 01.2004
- Was responsible for developing Vibration analysis for the 797 Mining Truck Transmission
- Once process developed and validated it was then implemented on all Test Stands in Transmission Test Facility.
- Develop Transmission Test cart to be used at a Caterpillar dealer remanufacturing facility
- Test cart would collect vibration data and transmit to offsite facility where data would be analyzed
- Once data analyzed (within 2 min) a confidence decision would then be transmitted back giving test operator a go / no go decision
- Data collected and analyzed then added to a statistical database for further predictive capabilities.
- Project - Caterpillar Solar – San Diego, California - Assisting in the development of a process that takes dimensional manufacturing data and associates it with a tested product to produce a model that can be used to predict outcome of tests based on the combination of manufactured parts
- Patent was awarded and had the potential to save Solar > $25 million on first test pass rate
- The validated process from Solar was then used as a Model project for Caterpillar Pontiac injectors, which led to improving their first test pass rate on injectors.
- Research Project manager: FMEA software solutions that can be used as a migration path to an Expert System.
- Research Project manager: RISK model to establish a process and or tool set that can describe the component failure risk for complex assemblies, the entire vehicles, and provide as a guide to establishing reliability targets early in the NPI program.
Quality Engineer
Caterpillar Tractor
01.1998 - 01.2000
- Collaborated with Caterpillar Transmission customers, product engineering staff, and product manufacturing / assembly people to resolve transmission quality issues.
- Assisted in the definition, design of Vibration analysis as it applies to transmissions.
Education
Skills
- Project management
- Lean Manufacturing (5S, Value Stream Mapping, Flow, QCO, Toyota Production System)
- Microsoft Office products (Excel, Word, PowerPoint)
- Database Structure (Statistics (6 Sigma))
- Quality and Reliability tools (SFMEA, PFMEA, FME)
- Test applications
- Manufacturing methods
- Vibration analysis
- Supervision, Line, Section, Facility)
- Human relations / Change Management (Union / Management)
Certification
- Patent Awarded – Utilizing Neuro Networks to isolate defective dimensional piece parts in Solar Turbines
- Certified 6 Sigma Black Belt
- CPS Black Belt
- 6 Sigma Black Belt
Additional Information
(Community involvement) Past President of Illinois Valley Striders running club. As President of this large club (700 members) my organizational responsibilities include overseeing club finances, training programs, community events, alliances with organizations such as the local Park District, overseeing technology as it pertains to racing events, race scoring, sponsor relationships and committee member for the clubs premier running event the “Steamboat Classic”.
Military Service
1968 - 1972 U.S. Air Force Vietnam campaign
Alternative Email
weisracecar2017@gmail.com
Hobbies and Interests
Motorcycling, Wood working (furniture, build / remodel homes), Avid Runner (over 1000 road races, 14 marathons, Training director for Building Steam (400 runners per year), Water skiing (Ill State Champion in Barefoot water skiing))
Timeline
Contract Sr. Industrial Engineer
ACTalent (General Motors, Springhill Assembly Plant)
10.2022 - 05.2024
Contract Industrial Engineer
ACTalent (US Tobacco)
10.2021 - 06.2022
Contract Lean Engineer
TWIG Products
01.2020 - 07.2020
Contract Lean Engineer
Simpson Strong-Tie
11.2018 - 05.2019
Contract Lean Engineer
NTN bearing
01.2016 - 06.2018
CI Manager
Nelson Global Products
01.2014 - 01.2016
Supplier Development
Caterpillar Global Purchasing
01.2010 - 01.2014
Development Engineer
Caterpillar Production System
01.2006 - 01.2010
Operations Manager
Caterpillar Tractor
01.2005 - 09.2005
Development Engineer
Caterpillar Tractor
01.2000 - 01.2004
Quality Engineer
Caterpillar Tractor
01.1998 - 01.2000
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