Expert Details

Expert in Lean Manufacturing, Constraint Analysis/Resolution, New Product Planning, Manufacturing Engineering

Expert ID: 721981 Ohio, USA

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Expert Kopstein (formerly Even) works with management and plant teams in the evaluation and implementation of advanced technology integration, efficiency improvement, waste reduction and productivity. Compliance and implementation of quality systems including aspects of ISO 9000, strategic planning, cost containment, cost-of-quality, utilization of self-directed work teams, evaluating material sources and subcontractors, benchmarking, systems and organizational reengineering, shortening manufacturing cycles with reduced waste for cost containment are areas where Expert leads in adding value. Allocation of management resources, development of information management data collection and processing, planning for change, day to day operation, manpower and capacity analysis are additional areas of support that Expert provides.

Expert conceptualizes solutions to automate and integrate automation in existing and new processes. Expert leads in implementation and optimization of automatic process, cycle time improvement, utilization of machine elements and person to machine interfaces. Expert assesses investment efficiencies, safety and quality to assure effectiveness of proposed solutions.


Expert has spent over 28 years in manufacturing; improving, and installing integrated systems of people, materials, automation and other equipment. He also has extensive experience in the development of specific and general use of automation.
Expert conceptualizes solutions for automating and integrating automation in existing and new processes. Expert leads in implementation and optimization of automatic processes, cycle time improvement, utilization of machine elements and person to machine interfaces. Expert assesses investment efficiencies, safety and quality to assure effectiveness of proposed solutions. In addition Expert leads product and process design, automation and robotics, cost justification and control. This encompasses different industries where continuous process and production lines as well as discrete work cells are prevalent.



Expert is experienced in planning, building, and implementing manufacturing processes. This includes product and process design, automation and robotics, cost justification and control, product scheduling, and overall quality management. While he worked primarily in the Automotive assembly and manufacturing field he is familiar with various other disciplines, including ISO 9000 ISO 14000 requirements, Just-In-Time (JIT), inventory control, information systems and safety.
Expert has led teams developing assembly processes for new products, work allocations and optimization, layouts, in process work flow, sequencing, in line sequencing, adapting and complying with synchronous material flow requirements. Adapting product design for manufacturability, establishing takt times and alignment of process, product, people and tooling. Expert has experience coaching process mapping, value-added analysis, work simplification and streamlining, work measurement, and Lean Operations. Expert has led teams developing assembly processes for new products, work allocations and optimization, layouts, in process work flow, sequencing, in line sequencing, adapting and complying with synchronous material flow requirements. Adapting product design for manufacturability, establishing takt times and alignment of process, product, people and tooling.


Expert has 28 years of experience in manufacturing at all levels of responsibility from an engineer to a supervisor, department manager, operations manager, and program manager. He is versed in all aspects of the business - maintenance, projects, engineering and production including new models' introduction, capacity, quality, safety, cost and customer delivery current requirement and forward planning. Expert works with management and plant teams in the evaluation and implementation of advanced technology integration, efficiency improvement, waste reduction and productivity. Compliance and implementation of quality systems including aspects of ISO 9000, strategic planning, cost containment, cost-of-quality, utilization of self-directed work teams, evaluating material sources and subcontractors, benchmarking, systems and organizational reengineering, shortening manufacturing cycles with reduced waste for cost containment are areas where Expert leads in adding value. Allocation of management resources, development of information management data collection and processing, planning for change, day to day operation, manpower and capacity analysis are additional areas of support that Expert provides.


Expert has been in the automobile manufacturing industry for over 28 years and has experience in all aspect of the manufacture and assembly processes. His managerial experience encompasses manufacturing and engineering with teams working on identifying and correcting quality, inventory, and production control problems Additionally Expert has had a leadership role in implementing Lean Manufacturing, theory of constraint, SPC and other continuous improvement techniques. Expert has experience coaching process mapping, value-added analysis, work simplification and streamlining, work measurement, and Lean Operations. Expert coached and led cross-functional teams of operators and support personnel in continuous quality improvement and team-based problem solving. He also has extensive experience in the development of measurements and standards for manufacturing and maintenance. Mistake-Proofing (Poke-Yoke).
Expert works with plant personnel to establish corrective actions in the areas of product quality, process capability, equipment up-time and hardening. Expert corelates measurables to the efectiveness of proposed corrective actions and develops 'best' approaches.


Expert has led the development, planning and execution of multi million dollar projects supporting: product changes, new products, capacity requirements, quality, safety and expansions. He also led major projects implementing organizational changes, business unit reorganizations and new launches of new product lines including process, facilities and people. He believes in meeting all deliverables: safety, quality, timing, delivery and cost and executes to consistently meet these objectives.

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An electronics assembly plant needed help launching a new automatic assembly process, which included automatic component placement, testing, soldering, prepackaging, and final assembly. It required multiple end items with total traceability in the process. The plant fell behind schedule and quality did not meet targets, which caused two assembly plants to shut down. Within two weeks of the onset of project, which consisteed of corrective engineering, lean manufacturing, quick change-overs, optimization of automation application and team interaction throughput was increased by 80-90%. A continuous improvement program was developed to sustain the process. A body assembly process capacity was 15% below its desired outcome due to machine capability and effectiveness limitations. Expert evaluated a proposal to invest over $4 Million in capacity enhancement. He identified and implemented tooling and sequencing opportunities on the constraint tools and accomplished the desired capacitiy with a less than a $30,000 expenditure.A major conveyor system was deemed to control total assembly output. Expert analyzed the overtime data and reviewed physical equipment for adequacy. He then identified the required facility revisions to improve effectiveness, cycle time reductions and major safety concerns. In the end, he refocused the customer on the true constraint.Capacity far exceeded demand and repetitive down weeks were mandated at a large company. Utilizing total long term cost, a capacity action was developed and implemented to reduce costs by over $20 million within 3 years.

Expert may consult nationally and internationally, and is also local to the following cities: Detroit, Michigan - Warren, Michigan - Livonia, Michigan - Dearborn, Michigan - Cleveland, Ohio - Toledo, Ohio - Akron, Ohio - Youngstown, Ohio - Canton, Ohio - Erie, Pennsylvania

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Education

Year Degree Subject Institution
Year: 1989 Degree: Subject: Executive Development Program Institution: Kellog School of Management, Northwestern University
Year: 1971 Degree: M.S. Subject: Electrical Engineering Institution: IIT
Year: 1970 Degree: B.S. Subject: Electrical Engineering Institution: IIT

Work History

Years Employer Title Department Responsibilities
Years: 1997 to 2000 Employer: Ford Motor Company Title: Manufacturing Planning Manager Department: Vehicle Operations, Ohio/Lorain Assembly Plants Responsibilities: The scope of Expert's work included implementation of corporate process initiatives such as TPM, Ford Production System, In-Line Vehicle Sequencing (ILVS), Vehicle Quality Subsystem, ISO 14000, waste minimization, energy use and cost, operational cost and uptime improvements, and safety initiatives. Expert's core responsibility was for overall facility maintenance, capital budgets, CIM infrastructure and support systems, and new product program planning and launches. The organization included up to 31 salaried personnel and over 130 hourly employees.
Years: 1996 to 1996 Employer: Ford Motor Company Title: Launch Manager 99 MY Department: Vehicle Operations, Ohio Assembly Plant Responsibilities: Expert was responsible for quality planning, vehicle assembly process and content, processing, facilities, training development, overall budgeting and implementation.
Years: 1995 to 1996 Employer: Ford Motor Company Title: Manufacturing Engineering Manager Department: Vehicle Operations, Ohio Assembly Plant Responsibilities: He was responsible for process capabilities, throughput, facility maintenance and uptime, labor productivity, and forward model planning.
Years: 2001 to Present Employer: Undisclosed Title: Consultant Department: Responsibilities: Expert provides consulting services to manufacturing operations, including resolution and implementation of capacity, constraints, management operating system, quality, and forward planning.
Years: 1992 to 1993 Employer: Ford Motor Company Title: Body Assembly Area Manager Department: Body & Assembly Operations, Wayne ISA Responsibilities: Expert was responsible for manufacturing, quality, cost, forward model planning, and implementation of all company initiatives. The organization consisted of over 700 personnel.
Years: to Present Employer: Undisclosed Title: Body Assembly Area Manager Department: Body & Assembly Operations, Ohio Truck Plant Responsibilities: In this role, too, he was responsible for manufacturing, quality, cost, forward model planning, and implementation of all company initiatives. The organization consisted of over 700 personnel.
Years: 1990 to 1991 Employer: Ford Motor Company Title: Shift Operations Manager Department: Body & Assembly Operations, Ohio Truck Plant Responsibilities: As Shift Ops Manager, he directed the total day-to-day plant operation: cost, safety, quality, procedures delivery and personnel.
Years: 1988 to 1990 Employer: Ford Motor Company Title: VN-58 Launch Coordinatior Department: Body & Assembly Operations, Ohio Truck Plant Responsibilities: Expert coordinated the planning and implementation of process, tooling, facilities, training and organizational preparedness for a major product change.

Career Accomplishments

Associations / Societies
Expert is a member of IEEE and SME.
Awards / Recognition
He received intracompany letters of recognition at Ford Motor Company.

Additional Experience

Training / Seminars
He delivered 'case for change' and 'lean manufacturing' overviews for middle management.
Vendor Selection
Expert has identified the proper tooling programs for a major body shop reskin, facilities for three major capacity actions, selection of on-site service and commodity suppliers, stamping assembly and automation for three stamping plant product programs.
Other Relevant Experience
Other noteworthy areas of special knowledge for Expert are: management of complex production operations in manufacturing and assembly; quality operating systems, planning and implementation; change leadership and being a change agent; lean manufacturing methodologies; Theory of Constraints applications; and strategic analysis and planning. He has also devoted much effort to product launches at many levels: process, tooling, facilities, organization and integration. Expert possesses strong manufacturing engineering skills -- from assembly, automation, tooling and facilities issues to the product itself. He has implemented organizational and functional management changes reducing management rolls by 12%. He developed best-in-class practices reducing emissions by 50% in booth and facility maintenance processes. He also led two process and product improvement teams to achieve 60% First Time Through improvement in two significant assembly processes.

Language Skills

Language Proficiency
Hebrew Hebrew is Expert's native language.
French Expert studied French as a first foreign language in high school. He describes his proficiency as "rusty but recoverable."

Fields of Expertise

factory management, plant operations management, production management, operations management, manufacturing, automation, manufacturing automation, factory automation, operations management, manufacturing, assembly automation, automated assembly, automated manufacturing, industrial automation, flexible manufacturing, robotic work cell, robotic assembly, assembly, assembly sequence planning, continuous flow manufacturing, high volume, low cost product assembly, manufacturing process development, production line, process engineering, production engineering, continuous motion assembly, operation analysis, manufacturing productivity, planning, production cost, productivity improvement, productivity measurement (quantity), automobile manufacturing, manufacturing troubleshooting, total quality management, yield enhancement, corrective action, robotic work cell, robotic assembly, assembly, project execution planning, project planning, high volume, low cost product assembly, manufacturing process development, production line, process engineering, production engineering, continuous motion assembly, operation analysis, manufacturing process design, planning, production cost, productivity improvement, productivity measurement (quantity), resolution, organizational productivity, labor productivity, technology integration, self-directed work team, machinery assembly, vacuum gripper, process planning, focused factory, metal manufacturing, production planning, electronics manufacturing equipment, product management, integrated management computer system, product manufacturing, electronics manufacturing automation, maintenance planning, welding robot, electronics manufacturing management, design for manufacturability, design for assembly, reliability prediction, computer-aided manufacturing, computer-aided design and manufacturing, design for manufacture and assembly, process automation, manufacturing control, robotics, quality control, production control, concurrent engineering, computer integrated manufacturing, automotive industry, automotive engineering

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