Expert Details

Expert in Manufacturing and Warehousing Facility Layout Planning

Expert ID: 730584 Pennsylvania, USA

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With more than 35 years of experience, Expert. Expert has held the positions of Vice President of Operations, Director of Engineering and Manager of Industrial Engineering. As a consultant with international experience, he has completed over 150 projects ranging from process improvement to the design and start-up of high tech manufacturing plants. As a manager in industry and as a consultant, Expert. Expert has served such companies as: AGCO, Clorox, Cottrell Trailers, The Lane Company, Proctor Silex, JLG Industries, Continental Tire, Thonet Industries, Hess Manufacturing, Kimball, Geiger Brickel, The Federal Reserve Bank, and others. Typical responsibilities have included:

• For a leading manufacturer of agricultural machinery, planned the re-layout of their largest sheet metal fabrication facility, from receipt of steel coil, through laser cutting, punching and forming. Identification of value streams among 8,000 unique parts, based on sheet gauge, part types and end use. Proposed improved material handling methods in conjunction with layout changes.

• Planned the layout and consolidation of two large welding shops into one – over 50 manual and robotic weld stations. Scope included storage of incoming parts and improved material handling methods to and from each weld station.

• Rearrangement planning for a maker of cosmetic and personal care products, from raw materials through compounding, filling, pack-out, and finished goods distribution. Improved material flow and floor-space utilization for capacity expansion.

• Design and set-up of high technology factories for the woodworking industry using of state-of-the- art process equipment, conveyors and automated material handling systems: Office furniture, custom kitchen cabinets, high end custom residential furniture, retail store fixtures, medium end bedroom furniture, work benches, counter tops, custom office furniture, medical furniture, architectural millwork…

• Design of chair manufacturing plants with lean workplace layout, equipment specifications, installation cost estimates and ROI.

• For a manufacturer of windows and doors: Planned and managed the consolidation of two factories into one with 50,000 square foot expansion. Doubled manufacturing capacity.

• Planned the consolidation of three printing plants.

• Reengineering and re-layout of the weld assembly shop for a leading manufacturer of automobile carriers. Line balance, ratio-delay studies to improve throughput and reduce flow times. Material handling and ergonomic improvements.

• Line balancing and process improvements, root cause analysis of process/product problems and facilitated problem solving with factory and management teams.

• Review of time standards, set-up reduction and flow time improvements for the machine and fabrication shops of a large agricultural implement plant.

• Extensive work with labor standards and job design to increase productivity and reduce costs. Conversion of legacy standards to predetermined time systems. Analysis of piece rate discrepancies. Establishment of labor grades and point systems to correct wage structures; writing of detailed job descriptions. Implementation of gain sharing.

Expert is a certified practitioner of Systematic Layout Planning (SLP). He is also a Certified Instructor for Maynard Methods Improvement and Time Study, certified in Detailed Work Factor, Basic Most, and Maxi-Most manual and computer predetermined time systems. Expert. Expert has been a speaker at international trade shows and at Purdue University. He is a member of IIE, APICS, SAVE International, and the American Society for Quality.


He has prepared detailed layouts for Work Aerial Platform & Mobile Platform Manufacturer - Layout 100,000 SF plant expansion for Fabrication, Assenbly and Warehouse.He prepared consolidation plans for a Large Printing Company - Consolidate 4 separate locations and corporate office into one location.He developed cost saving processes for a Sewing Machine Cabinet manufacturer - Re-layout to reduce cost, improve flow, reduce through-put time and improve material handling.He provided extensive analysis using predetermined time and motion standards for a Small Appliances Manufacturer - Re-layout factory including multiple overhead conveyors and add new product producing 4,000 units per 8 hour shift in existing floorspace.He has designed floorspace saving and labor saving technology for a Large Lumber Distribution Facility- Design, specify, RFQ, cost justification implementation schedule for conversion from dense stack congested storage to automatic storage retrieval system.

Expert may consult nationally and internationally, and is also local to the following cities: Baltimore, Maryland - Frederick, Maryland - Gaithersburg, Maryland - Bowie, Maryland - Allentown, Pennsylvania - Reading, Pennsylvania - Lancaster, Pennsylvania - Wilmington, Delaware - Alexandria, Virginia

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Education

Year Degree Subject Institution
Year: 1989 Degree: non-degreed Subject: Industrial Engineering and Physcology Institution: Liberty University

Work History

Years Employer Title Department Responsibilities
Years: 1997 to 2012 Employer: HAK Consulting Services Inc Title: President Department: Consulting Responsibilities: He is responsible for operating a consulting business providing management and engineering consulting to manufacturing and warehousing. He has prepared plant layouts, introduced new technology, developed new products, prepared training matreials and trained over 100 employees.
Years: 1990 to 1997 Employer: Hess Manufacturing Company Title: Director of Research and Development & VP of Manufacturing Department: Manufacturing Responsibilities: He was responsible for research and development of new products and P&L for manufacturing windows and doors.
Years: 1987 to 1990 Employer: Gunter Geiger Systems LTD Title: Senior Project Engineer Department: Consulting Responsibilities: He was responsible for development of major upgrade to new technology for the woodworking industry
Years: 1978 to 1982 Employer: JLG Industries Title: Manager of Industrial Engineering Department: Industrial Engineering Responsibilities: He established an Industrial Engineering department consisting of IE's, ME's and Tooling Engineers. Also supervised installation of work measurement system, trained junior IE's, developed new product cost estimates and prepared national and international plant layouts.
Years: 1974 to 1978 Employer: Proctor Silex Title: Chief Industrial Engineer Department: Industrial Engineering Responsibilities: He was responsible for introducing high volume small appliances into the existing production operation. Providing complete plant layout to produce 4,000 units in an 8 hour shift. He generated annual cost savings of over $600,000 throu product and process improvements. He worked well in the union environment and members of the bargaining unit.
Years: 1967 to 1973 Employer: Lane Furniture Company Title: Time Study Analyst Department: Industrial Engineering Responsibilities: He developed extensive standard data used for employee incentive pay and cost estimating of new products

International Experience

Years Country / Region Summary
Years: 1990 to 2003 Country / Region: Germany Summary: Two week trips to show clients advance technology and attend the Woodworking Fair.
Did not stay there the rest og the year only visited for 2 weeks every other year.
Years: 1995 to 1995 Country / Region: Japan Summary: Two weeks to visit prospective clients in Gifu and t additional follow-up trips to establish business in the Japanese market.
Years: 2009 to 2006 Country / Region: France Summary: Work with agricultural equipment manufacturer to develop plant/site layout plans
Years: 2010 to 2010 Country / Region: Mexico Summary: Multiple trips to Mexico to develop a study in expanding manufacturing operations in Mexico. Also in 2012 to develop new plant layouts for a machine shop.

Additional Experience

Expert Witness Experience
He provided expert witness for Columbia Plywood in Klamath Falls Oregon for a case invovling an employee loosing three fingers. The employee failed to heed company policy and tried to clean a machine while it was running. The jury found in favor of the company.
Training / Seminars
He presented Plant Layout Planning for International Woodworking Fair in Atlanta, GA
Best Practice for Sanding Solid Wood, Purdue University
How to Develop Work Measurement Labor Standards, National Conference on Operations Fulfillment
Vendor Selection
He developed specific requirements for vendors to quote on versus letting the vendor tell/sell you what they may think you need. Salesmen are often not qualified to evaluate the correct needs of the clients and the results are companies buying something they don't need.
Marketing Experience
He has provided cost saving insights for American manufacturing and warehousing that are currently wasting money and valuable resources of material and labor. The absence of proper layouts, material handling, work assist equipment and tools, advanced technology are required to eliminate the waste.
Other Relevant Experience
He is Certified in Systematic Layout Planning, Basic MOST, COmputer MOST and Computer MOST, Detailed Work Factor, and Counselor for Maynard Fundamental of Industrial Engineering

Fields of Expertise

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