Charles McManus

Background

About Charles McManus

Lean:• Used Kanban, Kaizen, & 5S workshops supporting JIT/ Kanban & cycle time reduction to maximize results in customer responsiveness, inventory availability & turn efficiency. • Used cell design, line balancing, & 5S, we reduced inventory and resource requirements by combining responsibilities, tearing down departmental walls, develop autonomous teams to tackle aggressive objectives, improved customers satisfaction in both quality and delivery. • Using Visual Factory methods, deployed Tiered Stand-up Meetings, focusing on daily metrics, data collection to identify & resolve quality, performance issues. Results, reduced lead times, increased throughput, improved quality and on time delivery performance.• Through 5S, and Kaizen improved performance of each manufacturing workstation, addressing ergonomic, safety, material flow, fixturing & tool requirements.• Deployed Preventive Maintenance programs improving downtime. Deployed on-line manufacturing instruction, Training Matrices / records • Through APQP, process mapping, FMEA, created control plans and procedures, to train, validating process capability and quality performance consistency. • NPI, Lead Manufacturing Team on time, on budget launch of a complicated multifaceted instrument. Manufacturing Team participated in Alpha and Beta instrument build, gave real time feedback to engineering Team. Results, a DFM instrument, superior in performance, time to manufacture reduced by 35%, FPY improved by 25%, reduced lead time by 2.5 weeks• Assumed leadership of Materials Team. Restructured Team, created Buyer / planner role. Created standard work, aligned buyer / planner to product line. Results, On Time Delivery performance improved from <80% to 95%. • Lead Team focused on Reducing Scrap, realized $700K YOY expense reductions• Deployed Calibration & verification data base to monitor and control critical measuring equipment and fixturing in adherence to ISO protocols