Market Trends, Lean Manufacturing, 5s, Six Sigma, One-Box Setup, Start-ups, Shutdowns, and Design
ID: 729682 Arizona, USA
At Smurfit-Stone Container in Phoenix, he had Quality and ISO 9001 responsibilities over 11 Pacific Region plants and Safety responsibilities over 11 Southwestern Plants. He was on the Smurfit-Stone Merger Mobilization Team consolidating operations and producing nearly $100 million in annual savings. For his “Value Added” sales efforts as a packaging Salesman Expert was nominated for the corporate wide Project XV Value Added Sales Award for the largest box manufacturer in the world at the time. Expert was one of the few people out of a pool of 30,000 nominated for the Stone Container’s Chairman’s Award for my Quality, Sales and Supply Chain efforts.
Expert managed three facilities for Temple-Inland (Fortune 1000) in Edinburg, Texas, Nuevo Laredo, Mexico and Reynosa, Mexico before shutting down the Nuevo Laredo, Mexico facility and expanding value added manufacturing at the other two. They totaled 380,000+ square feet, 150 employees and over $60 million in sales. He was the Chairman of the Board of Directors for the South Texas Manufacturers Association and on the Board of Directors of the United Way of South Texas. Expert has also served on the boards of several Corporations and Non-Profits in the past.
Before Temple-Inland he was General Manager of Manufacturing for Marfred Industries reporting to the CEO, in charge of the three sites of the Manufacturing Division. He merged the Corrugated Plant and Folding Carton plant together into one consolidated manufacturing operation, improving efficiencies and profitability of both division P&L’s. He more than quadrupled their Value Added Sales increasing gross margins and attaining over $55 million in sales.
At Gaylord Container Expert and the team implemented a Quality Transformation that made us the runner up for the Governors Quality Award for the state of Arizona, “The Pioneer Award”. They turned a plant that had been losing money into the top performing plant in Gaylord making $4 million in net profit one year. This team won the Corporate Top Performing Plant award for Gaylord for four straight years during his six year tenure there out of 26 plants.
Expert has spoken at National and Local Conferences for RISI, Paperboard Packaging Group, Institute of Packaging Professionals, American Society for Quality, South Texas Manufacturing Association, University of Texas Pan American, South Texas College, Manufacturing Summit and many others.
As President and Chief Consultant of a consulting firm, Expert has done Expert Witness with his most recent project saving the insurance company over $1 million. He is also a packaging design and branding expert for Packaging Launch.
Expert' last Expert Witness consulting project saved the client over $1 million. It was a case where a building fire damaged manufacturing machines and equipment. He determined Fair Market Value, Cost to Build (New), Cost to Rebuild and Assessment of equipment condition and value prior to fire.He has done Consulting projects with Investment Banks. One was a determination of what potential consolidation savings could be attained by two Fortune 1000 Packaging Companies merging. What redundant capacity could be removed and what profit improvement could result in the combined scale of the companies.He is currently working on a Market Feasability study to determine which of three markets would be the best to open a brand new state of the art Corrugated Plant (with Corrugator).He has done Keynote Speaking for companies and associations.He has done training on Profit Improvement, 5s, Lean Manufacturing, Lean Six Sigma, Quality Improvement, Safety Leadership, OSHA, Forklift Training, Hiring the Best, Cost Control, Value Added Sales, Consultative Sales, Enterprise System Set Up and much more.
|Degree: 3.95 GPA (BSBA Degree Not Completed)
|Subject: Business Administration
|Institution: University of Phoenix
|Years: 2010 to Present
Responsibilities:President and Chief Consultant. Keynote Speaking, Training, Expert Witness and Consulting on Packaging, Manufacturing, Organizational Improvement, Lean Six Sigma and more.
|Years: 2010 to Present
Responsibilities:Run a recruiting and Human Resources services company.
|Years: 2008 to Present
Responsibilities:Run an industry association for paper based packaging with over 4,000 members.
|Years: 2007 to 2010
|Title: General Manager
|Department: International Group
Responsibilities: Manage Plants in the US and Mexico
Full P&L and Budgeting Responsibility
Increased Value Added Sales by 232%
Improved Profits by over $3 Million in 2009
Highest Productivity in the History of the Plant
Improved OHSA Recordable Rate from 8.4 to 0.75
Reduced Lead Times by 85%
Expanded sales into Central America
Improved On Time Delivery From 92% to 99.3%
Implemented Lean Six Sigma
Increased Selling Margins 34%
Improved Net ROI by 91%
Reduced Tooling Cost by 40%
Reduced Labor by over $1 Million
Asked by the Vice President of the International Group to turn around the three operations in South Texas and Northeast Mexico. These operations had declining Sales, Contribution Margin and Profit. These operations were near the bottom of the company out of 64 plants in Profit, Safety, Cost of Goods Sold, Productivity, Waste, and Quality. My team choreographed one of the best turnarounds in Temple-Inland history. This turnaround included ceasing operations in Nuevo Laredo, Mexico and adding manufacturing capabilities to the facility in Reynosa, Mexico. My operations earned the only Strong rating ever given by Temple-Inland for Financial Audit results and one of the few Strong ratings ever given for Safety Management System Audit results. Temple-Inland is the third largest manufacturer of Corrugated Packaging in North America and was voted Most Admired in Fortune Magazine three years in a row.
|Years: 1999 to 2007
|Employer: Marfred Industries
|Title: General Manager of Manufacturing
|Department: Manufacturing Division
Responsibilities: Created Multi-Divisional Strategic Plans
Full P&L and Budgeting for Two Divisions
Managed Folding Carton and Corrugated Divisions
Directed Inside Sales for the Distribution Division
Saved over $750,000 in Net Purchases Per Year
Saved over $400,000 In Labor Per Year
Led Folding Carton Division to Profitability
Opened the Structural and Graphic Design Center
Created a World Class Corrugated Operation
Reduced Folding Carton Lead Times by Over 60%
Improved Productivity in Corrugated by 18%
Increased Productivity in Folding Cartons by 26%
Implemented Kaizen, Kanban, 5S, SMED and TOC
Implemented Lean Manufacturing and Deming
Formed Comprehensive Vendor Management System
Improved Vendor On Time Delivery From 93% to 99%
Reduced Folding Carton WIP by 77%
Chosen by the CEO to assume leadership and turn around the performance of the struggling Folding Carton Division in September 2004. Challenged by the CEO to assume control of the Distribution Division Inside Sales Group in September 2006 to improve sales and customer focus in order to turn declining annual sales into sales growth. Led the Folding Carton Division to profitability and beat industry averages in sales growth in distributed products. Installed In-House Graphic Design and Computer to Plate Systems to reduce lead times and improve margins. Utilized Vital Statistics to create teams to improve performance in weak areas. Marfred Industries is a $75 million independent family owned corporation. Marfred Industries manufactures Corrugated Boxes, Folding Cartons, Litho Labels, Ink, Printing Plates, cutting dies, and has in-house graphic design, structural design, branding, and marketing. They also distribute thousands of packaging and janitorial supplies through their Distribution Division. (www.marfred.com)
Exceed TAPPI Excellence Goals for Productivity
Exceed TAPPI Excellence Goals for Waste
Full Divisional P&L and Budgeting Responsibility
Increased Value-Added Sales by $2.1 Million
Selected to be the General Manager by the CEO to lead the $30 million Corrugated Division to “World Class” status. Doubled the size of the operation and created one of the newest state of the art facilities in North America making strong profits in a down economy.
|Years: 1996 to 1999
|Employer: Smurfit-Stone Container Corporation
|Title: Quality Assurance Manager
|Department: Container Division
Responsibilities: Nominated for Corporate Chairman’s Award 1998
Nominated for Project XV Sales Award 1998
Employee of the Year 1998
Co-Wrote ISO 9001 Procedures
Achieved ISO 9001 Registration for multiple Plants
Lead ISO 9001 Quality Auditor for the Pacific Region
Safety Champion for the Southwest Region
Trained by Bain Capital on Merger Integration
Achieved and Maintained AIB – Superior
Ran the Corrugated Testing Lab (Mullen, ECT, etc.)
Account Manager for $7.5 Million in Sales
Improved Safety Incident Rate From 8.6 to 3.2
On the Smurfit-Stone Merger Mobilization team challenged with consolidating operations to save over $50 million per year. The team saved almost $100 million. Implemented the first Stone Container JIT II (Cooperative Alliance) system with a $6.5 million account in Mexico. Reduced the number of quality errors at the Glendale Plant by over 30%.
|Years: 1990 to 1996
|Employer: Gaylord Container Corporation
|Title: Lead Supervisor
Responsibilities: Best Performing Plant 1992 through 1995 (26 Plants)
Finalist for the Governor’s “Pioneer Award” for Quality
Process and Procedure Training Manager
Assistant Design Engineer
Improved Safety Incident Rate from 15.7 to 4.8
Outstanding Employee Award
Started up a new Specialty Sheet Plant. Ran Corrugator, Flexo, Diecutting, Finishing, Shipping, Sheet Plant and Maintenance Departments simultaneously at two manufacturing and distribution facilities. Supervised three Foremen and over 60 employees while directing all plant training. Gaylord Container was a $1 billion corporation that is now part of Temple-Inland. This is a Union facility. (www.Temple-inland.com)
|Country / Region
|Years: 1997 to 1998
|Country / Region: Mexico
|Summary: Formed a Cooperative Alliance as an In-Plant with a $6.5 million customer. He handled the cust opers purchasing, order scheduling, and any issues with customs, accounting, logistics and more. He had an FM3 Work Visa.
|Years: 2007 to 2010
|Country / Region: Mexico
|Summary: He ran a Manufacturing facility and a Distribution Center for Temple-Inland in Reynosa, Tamaulipas, Mexico and Nuevo Laredo, Nuevo Leon, Mexico. He shut down the Nuevo Laredo facility after just over a year to consolidate operations in Reynosa. He had an FM3 Work Visa for the three years he ran these operations.
|Associations / Societies
|Appointed to the “Advisory Board” of Paperboard Packaging Magazine in 2010;
Founded the Paperboard Packaging Group- recruited 4000+ members in over 30 countries;
Director – Paperboard Packaging Group Expo 2010 “Leading World Class Performance;”
President of the Board of Directors, South Texas Manufacturers Association;
Leader of the 2010 Strategic Planning Committee to Create the new Vision, Mission and 3 Year Plan;
Packaging, branding and manufacturing expert for worldwide Packaginglaunch.com Website;
Member of the Board of Directors of the United Way of South Texas;
Member of the Board of Directors for Tucson Transatlantic Trade Holding Group;
Senior Member of the American Society for Quality (ASQ) – Customer Supplier Division;
Vice-Chairman of Administration for the ASQ Customer-Supplier Division;
Vice-Chairman of Membership for ASQ-Customer Supplier Division;
Track Manager – ASQ-Customer Supplier Division Annual Conference;
Oversaw the Bylaws Committee, Examining Committee and the Financial Auditing Committee;
Member of the ASQ-Customer Supplier Division Strategic Planning Committee;
Member of the Technical Association for the Pulp and Paper Industry TAPPI.
|Licenses / Certifications
|Certified Quality Engineer;
Certified Quality Manager;
Certified Quality Auditor;
ISO 9001 Lead Auditor.
|Awards / Recognition
|Best Achievement of Organizational Improvement in Manufacturing Award Given by the Six Sigma and Business Improvement Awards;
Employee of the Year - Smurfit-Stone;
Best Performing Plant Award - Four Consecutive Years - Gaylord Container;
Runner Up - Arizona Governor's "Pioneer Award for Qualty;"
Nominated for the Stone Container Chairman's Award (out of over 30,000 people);
Nominated for the Stone Container Value Added Sales Award.
|Publications and Patents Summary
|Invented a Recyclable Corrugated Pallet. He is also the author of several journal articles and has presented at numerous conferences.
|Expert Witness Experience
| Expert Witness Categories: Packaging, Manufacturing, Distribution, Warehousing, Freight, Load Securement, and Intellectual Property
He has been involved in labor litigation, corporate litigation, trained on antitrust and his most recent Expert Witness project savet the client over $1 million. A manufacturing plant burned down and there was a custom one of a kind machine (similar to others) that was burned up. Expert had to determine fair market value, build value, rebuild value, etc. which resulted in reducing the exposure of the Insurance Company by over $1 Million. He is very familiar with fires, floods, etc. and can help companies justify their values or help insurance companies avoid being cheated by companies exaggerating their claims.
|Training / Seminars
|He has trained these topics at national conferences: Leading World Class Performance, Lean Manufacturing, Performance Improvement, Improving Profitability, Building World Class Teams, Value Added Selling, Hire the Best..Fire the Rest, The Future of Quality in Corrugated and more.
He has also developed training programs for Safety, Quality, Productivity, Lean Manufacturing, 5S, Profit Improvement, Hiring, Consultative Sales, Value Added Sales, Box Manufacturing, Packaging Sales, Waste Reduction, Machine Set-Up, Diecutting, Printing and more.
|He knows most of the suppliers and vendors in the Corrugated and Folding Carton industries and has relationships with many of them.
|He stays current on linerboard and medium pricing as well as trends on OCC and supply and demand indicators.
|He can get by taling about business and manufacturing in Spanish but has a rather limited vocabulary.
Fields of Expertise
brand valuation, business analysis, business process management, business process re-engineering, business strategy, business valuation, change management, continuous flow manufacturing, enterprise resource planning, factory management, flexible manufacturing, human-factors industrial design, industrial engineering setup time reduction, inventory management, job shop operations, maintenance management, manufacturing cost control, manufacturing facility design, manufacturing process development, manufacturing productivity, manufacturing profitability, manufacturing resource planning, market trend, marketing brand management, materials management, mergers and acquisitions, online branding, operations management, organization redesigning, package cost reduction, package manufacturing, packaging machine performance, packaging material system, packaging-material management, plant management, process optimization, product management, productivity measurement, quality management, strategic branding, strategic management, strategic marketing, strategic planning, total quality management, world-class maintenance, music industry, value proposition, return on investment, product evaluation, sales management, mergers and acquisitions financial analysis, branding, gap analysis, printing productivity improvement, market development, merger, business ethics, small business, entrepreneurship, consumer purchasing behavior, lean manufacturing, build-to-order, mass customization, line balancing, allocation modeling, first article inspection, self-directed work team, business management, packaging material selection, order entry software, integrated product team, manufacturing cost analysis, ideation, operation analysis, manufacturing lead time, work team, lead time, world-class manufacturing, workforce management system, corrugated packaging material, office productivity, defect control, enterprise resource planning software, total productive maintenance, cosmetic product package, implementation, packaging specification, recyclable packaging material, inventory control system, manufacturing model, inventory reliability improvement, package integrity, product design variation reduction, packaging printing, material manufacturing, protective packaging material, product development cycle time, productivity improvement, packaging machine, manufacturing process optimization, packaging development, redesign process, productivity measurement (quantity), operations research, environmentally friendly packaging material, acquisition, business system design, manufacturing facility, job shop, market research, service marketing, packaging standard, marketing, waste reduction, product optimization, manufacturing control, packaging material, project management, process assessment, capacity planning, packaging paper, packaging process, kanban, just-in-time inventory, manufacturing cell