OBJECTIVE:
Manufacturing or Distribution Center Contract Industrial Engineering Consultant specializing in parts materials handling mechanization, direct labor control systems and product automation work cells.
SUMMARY:
· 200 productivity systems installed in warehouse, fabrication, assembly and work-in-process for 50 plus corporations in 30 years.
· Product knowledge in sheet metal, plastic, wood, aluminum, thermo-electric, electrical, mechanical and electro-mechanical
· Installed 100 production lines for over 1000 finished goods unique line balances
· Business acumen in marketing, industrial engineering and operations management.
PROFESSIONAL
EXPERIENCE:
JD GRAY ASSOCIATES, Summit Hill, PA (1977 to Present)
Contract Industrial Engineering Consultant
Clients
Burroughs, Harowe Motors, Concurrent Computer, Voltronics, National Fiberstock,
Warner Electric, General Electric, TE Technology, Lumex, Singer,
Interdynamics, Isolette, Tellurex, Milton Ross, Westinghouse,
US Steel, Child Master, International TE, Port- A – Crib, Maquila Twin Stroller,
Union Switch, H & H Smith, Hydro-Temp, Clay Adams, Allegheny Ludlum,
Automatic Switch, Perkin Elmer, Newport News Ship, Ballantine Labs, ECR International,
Hecon, Strolee, Dorma, NAP Lighting, Interline DC,
Melcor, Cadillac Rubber, Mexicali Stroller, Van Dyk Research, Wegmans DC,
Audio Systems, Spraque Devices, Graco, Ohaus Scale, Pepsi DC,
Syntrex, Xerox, Chariot, Brown Boveri, Anniston Army Depot,
Circle F Industries, General Motors, Magnavox, Heinemann Electric, Heatcraft Refrigeration
Most Recent Manufacturing Installations
Allegheny Ludlum Corporation – Provided the industrial engineering design of a variable gain sharing incentive plan affecting ninety-four direct and indirect plant wide hourly factory workers in a coiled steel processing facility. Development of primary measurement alternatives. Development of weighted comparison criteria. Assist in selection of primary measurement alternative. Assist in scope of primary measurement alternative. Assist in frequency of primary measurement alternative. Development of secondary measurement alternatives. Assist in selection of secondary measurement alternatives. Assist in scope and frequency assignment of secondary measurement alternatives. Assist in assignment of primary and secondary relative weight to one another. Development of performance pay charts using Excel spread sheets based on historical indices. Written variable gain sharing incentive plan procedure. Liaison with payroll and data processing personnel. Assist with implementation of variable gain sharing incentive plan.
ECR International – Performed return-on-investment analysis for six divisions of major HVAC Corporation
to determine consolidation feasibility. Industrial Engineering activity included time study, conceptual layout, conceptual equipment specification and costing, cost versus savings and report. Detailed implementation activity including snap back time study, line balancing, workstation / departmental Word drawing layouts and precision indexing rotary table equipment specification for two of the above six divisions. Direct labor savings of 50%.
Heatcraft Refrigeration Corporation – Assist in the transformation of a progressive gravity roller assembly conveyor for commercial air conditioner products to a paced assembly system utilizing two (approximately) fifty feet long by three feet wide indexing linear slider bed conveyors with preset dwell time PLC control panels, pause buttons and traverse warning lights. Industrial Engineering activity included on-site time study of eight families (different build sequences) on six fan sizes; equipment specifications, forty-eight optimum and sixteen alternative line balances; work station layout, part bills of material, parts containerization, visual aids, task instructions and tooling; on-site crew training and system implementation. Direct labor savings of 30%.
Distribution Center Installations
Wegmans – Industrial Engineered Standards in receiving – inspect and verification, automatic storage and retrieval system – pre pallet storage, automatic storage and retrieval system – pre stock pallet storage, stock pick location with pallet, pick and pack frozen food package on shipping pallet, shrink wrap pallet, shipping – load truck.
Interline – Work flow analysis in high and low volume pick areas, Optimum method development for manual pick from flow rack and for fork truck pick from pallet rack, Materials Handling on live storage and retrieval carousel specifications, Robotic specifications for carousel tote removal, Manual and automated layout alternatives, Cost justification for automated storage and retrieval system.
Pepsi – Industrial Engineered Standards in pallet repair – pick case – locate on pallet – place case on truck -
damaged cans sortation.
Newport News Naval Shipyard – Four Consolidated Building Alternatives, Part and stock location identification for eight warehouse facilities, optimum layout development.
JD Gray Associates Direct Labor Control Systems
Development of unit cost expectation, hourly accountability and shift output requirement.
Optimization of workflow, personnel and thru put.
· Time Study, Standards and Methods enhancing productivity
· Layout resulting in capacity increases
· Short-Interval-Scheduling systems that corrected chronic shortages
· Labor Reporting, identifying operator performance
· Staffing Tec...
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