David W. Stokes
Mansfield,USA
Summary
Accomplished and forward-thinking executive with over 30 years of expertise in operations and quality leadership for domestic and global manufacturing sector businesses. Cultivates rapport to optimize project goals and output, resolve complex problems, and deliver innovative improvement strategies. Proven record in developing teams that strengthen business operations and develop client-driven strategies, resulting in improved customer experience, productivity, operational efficiency, quality, and safety. Exceptional ability to inspire teams to drive profits through million-dollar cost reductions and multi-million-dollar capacity improvements.
Overview
23
23
years of professional experience
Work History
Business Operations Contract Consultant
Module X Solutions
01.2022 - Current
- Developed Strategic Capacity Growth Plan to support business growth to $150m in sales over next 5 years
- Included targets in EBITA growth, workforce development by key trade and standardization to drive out waste in both manufacturing and business processes
- Identified key capital spending to support this growth, all with paybacks in less than 8 months
- Typical was the development of a production line that would take output from 0.6 units per day to 8/10 units with EBITA from $5,000 to $21,387/day
- Analyzed employee turnover, then led a team that implemented an electrical apprentice program and a pay-for-skills program for non-apprentices
- Reduced electrician turnover by 30%
- Developed staffing plan with labor requirements by key skill category to support business needs based on hours sold
- This had never been performed before
- Developed manufacturing options for production lines and production cells and demonstrated that current methods were not cost effective
Operations Manager (Multi-Location)
Thermo Bond Buildings, LLC
01.2020 - 01.2022
- Managed all engineering and operations activities for the business
- Included manufacturing operations in Elk Point, SD and Elkhart, IN
- Staff – 180
- Developed Ramp to 50 Plan and grew manufacturing capacity from $24M to $38M within two years, to support strong sales growth from $26M to $51M
- Expect capacity to reach $45M by mid-2023
- Launched Lean manufacturing program for the business
- Applied for and used State Grants in South Dakota and Indiana to pay for this training
- Implemented a Non-union Apprentice program at the Elkhart manufacturing facility, to attract and incentivize potential electricians to become journeymen in a tight, post-covid labor market
- Implemented a program for process, and design standardization between the two plants
- Coached plant managers to focus, relax and optimize their plants
Field and Operations Support Manager
Trans American Power Products
01.2018 - 01.2019
- Company Overview: Manufacturer of structural steel, monopole designed towers for the power transmission industry
- Managed the project support function for TAPP field client relations
- This included aftermarket projects, client support, supply chain improvement and lean/continuous improvement activities
- Employees – 1 salaried
- Report to VP Client Relations
- Moved the factory to the field! Designed and set up 8 production lines to rework products in the customer’s lay-down yard
- Successfully managed high visibility, field rework project under challenging conditions, which met all client expectations
- Manufacturer of structural steel, monopole designed towers for the power transmission industry
Operations Manager
Fluidic Techniques a Division of Wika
01.2015 - 01.2018
- Company Overview: Manufacturer of ASME B31.1 and B31.3 differential pressure flow control products for the oil and gas, power generation and chemical industries
- Managed manufacturing operations for the Mansfield plant
- Responsible for production planning, manufacturing activities for welding, machining, assembly and test, facility management, capital planning and continuous improvement Kaizen teams
- Staff - 18 direct and 1 indirect, budget $7M (with material)
- Report to General Manager
- Applied team leadership abilities to design and built a $3M factory around value streams which minimized lead time, reduced costs and optimized customer experience and service
- Successfully completed new factory construction and start-up that doubled capacity
- Introduced and implemented SQDC metrics to focus the business on safety, quality, on time delivery and reduced costs
- Doubled overall output of the manufacturing operation from $500,000 to a consistent $1,000,000/month within 3 months
- Improved on-time delivery from 51% to over 94% in 12 months
- Documented and simplified operational procedures; reduced welding procedures from 150 to 18, simplified and streamlined manufacturing flows using Value Stream analysis methods
- Manufacturer of ASME B31.1 and B31.3 differential pressure flow control products for the oil and gas, power generation and chemical industries
Operations Support Manager
Valmont-Newmark
01.2012 - 01.2015
- Company Overview: Manufacturer of structural steel, monopole designed towers for the power transmission industry
- Managed the support function for the Valmont Mansfield manufacturing facility
- This included quality control, facility maintenance, EHS, environmental, supply chain improvement and lean/continuous improvement activities
- Staff – 8 direct, 2 indirect
- Budget $1.8M
- Reported to General Manager
- Identified critical process improvements that increased productivity and optimized sales per square foot of factory space by 25%
- Justified funding, then led $2M capital expansion to meet that goal
- Identified external suppliers to expand constrained capacity requirements for critical manufacturing processes
- Implemented SQDC metrics to focus the business on Safety, Quality, Productivity and Reduced costs
- Negotiated with building landlord to effect lease-hold improvements that had not been addressed in over 3 years
- Initiated / implemented TPM program to reduce unscheduled breakdowns, improve process reliability and operations productivity
- Manufacturer of structural steel, monopole designed towers for the power transmission industry
Engineering Services Manager
Flextronics Global Services
01.2011 - 01.2012
- Company Overview: Global contract manufacturer of cellular phone devices
- Managed the engineering team for a cellular phone, contract provider of Blackberry phones
- Responsible for initial facility design, layout, manufacturing flow, and production start-up activities
- Provided management leadership for product and process engineering functions and NPI activities
- Staff – 4 indirect
- Budget $2.6M, including capital
- Reported to Director Operations and Sr
- Quality Engineering Manager
- Led plant start-up project team
- Within 6 months, developed manufacturing facility layout, and designed and installed 23 configure, pack and ship cell phone production lines enabling the business to ramp to 250,000 units ($4.9M Sales, $3.5M COG) per month
- Led NPI (New Product Introduction) activities for all site product launches
- Global contract manufacturer of cellular phone devices
Sr. Manager, Quality
Nautilus, Inc.
01.2008 - 01.2010
- Company Overview: Manufacturer of cardio and strength fitness equipment for the sports and commercial fitness club industry
- Managed the quality team for Nautilus’ commercial equipment manufacturing facility
- Directed quality program for commercial manufacturing operations and was responsible for driving change and operational improvement in a business turnaround situation
- Staff – 4 indirect
- Budget - $300,000
- Reported to Sr
- VP Operations, Facilities, EHS and Quality
- Initiated effort then led team that wrote the organizations first Business / Quality Plan
- Developed and implemented welding process improvements that resulted in a 70% reduction in welding defects within 8 months
- Teamed with Nautilus Corporate and wrote a documented quality program compliant with ISO-9000
- Qualified offshore suppliers to improve their powder coat processes and provide rust-free product ready for use
- Manufacturer of cardio and strength fitness equipment for the sports and commercial fitness club industry
Owner
North Star Group, LLC
01.2004 - 01.2008
- Company Overview: Project turnkey supplier of commercial and residential flooring products to the trades, builders, and private customers
- Directed all sales, product selection, supply chain management, project management functions and customer service activities
- Managed subcontractor teams that supplied and installed products according to customer-specific schedule needs
- Started the business, full P&L responsibility
- Grew Revenue to $500,000 within 24 months
- Project turnkey supplier of commercial and residential flooring products to the trades, builders, and private customers
Corporate Quality Manager, Electrical Division
Thomas & Betts, Corp.
01.2002 - 01.2003
- Company Overview: Manufacturer and distributor of electrical supplies and products for the construction industry
- Managed the divisions Quality program and was responsible for continuous improvement initiatives, in a turn-around situation
- Responsibilities encompassed 15 manufacturing sites and 3 distribution centers throughout N
- America, Mexico, the Caribbean and Europe totaling $1B in sales
- Sole Contributor
- Reported to the Sr
- VP, Global Operations
- Deployed Lean Six Sigma program for the division
- Championed and coached 27 Black Belt candidates
- Realized $5M+ in financial benefit to the business, within 1st six months following implementation
- (Average of $200,000/project)
- Manufacturer and distributor of electrical supplies and products for the construction industry
Education
M.A. - Management
Webster University
B.S. - Metallurgical Engineering
Grove City College
Skills
- Capacity Growth Strategy
- Leadership Coaching
- Team Building
- Plant Design
- Construction
- Layout and Flow Analysis
- Business Turnarounds
- Strategic Manufacturing Operations Management
- Operational Planning
- Analysis
- Client-driven Continuous Improvement Program Development
- Lean Manufacturing Strategy
- Metrics Development
- Team Communication
- Accountability
- Quality System Development
- ISO 9000
- MIL-Q
- NQA-1
- 10CFR50 App B
- Operations management
- Continuous improvement
- Business analysis
- Performance improvement
- Planning and execution
Websites
Professional Highlights
- Developed strategy and led implementation of 3-year capacity growth plan to take company from $24M to $43M; Hit $42M in year 2.
- Moved factory to the field to reduce lead time and successfully deliver timely results during high profile rework project.
- Led team that optimized factory design around value streams and doubled output of operation from $500,000 to a consistent $1,000,000 per month.
- Developed plan that optimized order entry to product delivery process and cut lead time from 5 days to 2 hours.
- Refocused struggling Lean initiative by initiating and leading Lean Six Sigma deployment that realized over $5M savings within 6 months.
- Led plant start-up team that within six months ramped to 250,000 cell phone units and $4.9M per month in sales.
Training
- Six Sigma Black Belt Training
- ASQC Certified Quality Engineer
Timeline
Business Operations Contract Consultant
Module X Solutions
01.2022 - Current
Operations Manager (Multi-Location)
Thermo Bond Buildings, LLC
01.2020 - 01.2022
Field and Operations Support Manager
Trans American Power Products
01.2018 - 01.2019
Operations Manager
Fluidic Techniques a Division of Wika
01.2015 - 01.2018
Operations Support Manager
Valmont-Newmark
01.2012 - 01.2015
Engineering Services Manager
Flextronics Global Services
01.2011 - 01.2012
Sr. Manager, Quality
Nautilus, Inc.
01.2008 - 01.2010
Owner
North Star Group, LLC
01.2004 - 01.2008
Corporate Quality Manager, Electrical Division
Thomas & Betts, Corp.
01.2002 - 01.2003
B.S. - Metallurgical Engineering
Grove City College
M.A. - Management
Webster University
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