Todd Woodruff
Florence,KY
Summary
Professional Continuous Improvement Manager offering 18 years of experience managing improvement process programs. Successful in identifying problems to develop targeted solutions and implement employee training using lean principles. Focused on developing value stream mapping to analyze production and improve workflow processes. Expert in identifying risks and developing solutions that reduce chances of potential issues.
Overview
19
19
years of professional experience
Work History
Continuous Improvement / Operations Manger
Dana Incorporated
07.2021 - Current
- Lead Strategic Deployment (Hoshin) at Dry Ridge. Used MIRO to engage and visualize the team’s directives and plans to support the overarching goals of the company
- Developed Rapid Problem-Solving process and certification standards to support visualization of eliminating Problems on the shop floor
- Developed Leaders strategies for floor management and lead the Management Team through the Process. Daily Work for Shift Leaders, Group Leaders, and Team Leaders
- Helped launch Accountability and Core Team Meetings (FMDS) Visualizing Problem Solving and accounting for 15pcs/hr improvement on front axle lines
- Managed the Production floor through Program Change with ZERO Plant defects to customer and increased line output by 30%
- Led activity with Engineering and Maintenance to create full work and reduce 16 processes resulting in a savings of $928K annually
- Developed and trained Standardized Work process for Group Leaders to OWN and manage line changes and improvements from the facts of Process Observation
- Managed a floor of 553 direct manufacturing labor,3 Shift Leads, 15 Group Leaders and 45 Team Leaders through a six-month period of program transition.
Regional Lean Manufacturing Manager
Martinrea, International Inc
02.2016 - 07.2021
- Implemented and successfully completed the elimination of $5.8M in underutilized manpower by developing a minimum manpower Requirement tool to visualize work combination opportunities
- Worked directly with General Manager and Engineering to achieve High Frequency Delivery System, saving 19,000 Square feet and reducing start of production required manpower by 31 across three shifts Equaling $1.23 Mil annually
- Trained Continuous Improvement Managers in the use of lean tools to visualize and improve processes resulting in full work for line side operators and reducing manpower expenses by $1.5 Mil
- Led activity with Corporate Engineering to improve new model layout creating a flexible manpower line and reducing production manpower requirement by 24 operators equaling $1.2 Mil annually
- Lead team of engineers to realize robot cycle time reductions, eliminating the need for equipment expansion resulting in $1.2 Mil cost avoidance
- Calculated minimum and maximum inventory levels and set up a kanban production instruction system.
Specialist /Assistant Manager
Toyota Motor Engineering & Manufacturing North America Inc
08.2009 - 02.2016
- Benchmark and created assembly scrap problem solving system for Toyota Motor Manufacturing Texas & Mississippi, resulting in the elimination of $100.000 in scrap and expedite costs in the first month of implementation
- Studied low output Wheel manufacturing line and implemented conditional material flow logic to improve output by 1000 pieces a day
- Led vehicle Paint and Plastic Jishukens from developing strategy (A3) to coaching tools and seeing countermeasures through resulting in the development of shop core members and sustainment of cost reduction activities
- Created Visualization tool to separate normal from abnormal work to prioritize problems to solve one by one, resulted in eliminating 3 repair processes in the paint shop at TMMTX
- Monitored employee performance and developed improvement plans
- Set and enforced policies focused on increasing team productivity and strengthening operational efficiency
- Submitted reports to senior management to aid in business decision- making and planning
- Supported staff development and goal attainment by focusing on skill development and job satisfaction.
Production Group Leader
Toyota Motor
02.2005 - 08.2009
- Responsible for day-to-day operations on the Final Assembly six-cylinder Engine line (Safety, quality and productivity)
- Focused cost reduction activities to achieve department goals
- Managed 36 team members through multiple process changes as well as new model activity Developed and implemented standardized work training criteria for all assembly lines at TMMWV
- Developed quality-driven culture to boost team performance and efficiency while maintaining highly satisfied workforce
- Reorganized and enhanced employee training to close knowledge gaps and boost group performance
- Minimized resource and time losses by addressing employee or production issue directly and implementing timely solutions
- Applied performance data to evaluate and improve operations, target current business conditions and forecast needs
- Attended staff development meetings and workshops and applied information from those events into daily activities.
Education
Masters - Lean Manufacturing
OMDD Toyota
Erlanger, KY02.2016
Some College (No Degree) - Psychology
Seattle Central College
Seattle, WAHigh School Diploma -
Inglemoor High School
Kenmore, WA1988
Skills
- Toyota Business Practice Certified
- 8 step problem solving methodology
- Value Stream Mapping / MIFC
- Cost reduction
- Systems implementation
- Project management (10 years)
- Team leadership
- Process visualization / implementation
- Coaching
- Microsoft Office (10 years)
Timeline
Continuous Improvement / Operations Manger
Dana Incorporated
07.2021 - Current
Regional Lean Manufacturing Manager
Martinrea, International Inc
02.2016 - 07.2021
Specialist /Assistant Manager
Toyota Motor Engineering & Manufacturing North America Inc
08.2009 - 02.2016
Production Group Leader
Toyota Motor
02.2005 - 08.2009
Masters - Lean Manufacturing
OMDD Toyota
Some College (No Degree) - Psychology
Seattle Central College
High School Diploma -
Inglemoor High School
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