First I want to thank you for taking the time to review my profile. It certainly does take a great deal of time and selection to view someone here and I am glad you have taken the time to find out who I am.
To summarize myself for you:
Successful leadership shows extensive experience in diversified responsibilities including production, maintenance, facilities, tool & die, engineering, environmental / wastewater, programming, metal stamping / punching, forming, robotic & CNC machining, shearing, laser cutting, assembly, testing, packaging, shipping & receiving, purchasing.
Expertise in project planning and management with a talent for orchestrating resource demands and reorganizing technology groups to be more efficient and responsive to customer needs. History of exceeding revenue and profit targets. Looking to continue my career in a stable environment.
· 98% averaged on time delivery reliability, up from 25 to 74%; 3 of last 4 companies
· 92% averaged productivity rating, up from 78%; last 4 companies
· 74% averaged throughput increase while maintaining staff levels; last 4 companies
· 29% averaged reduction in manufacturing lead times, from 24 weeks to 17. last 3 companies
· 24% averaged increase in margins, from -10% to 34% last 4 companies
· 50% reduction in overtime, from 16 to 8 hours/wk average. Averaged last 4 companies
· 20% reduction of WIP – work in process Averaged last 4 companies
· 20% increase in manufacturing floor space by improving value stream. Averaged last 3 companies
Generated KPI’s/Metrics to track business objectives for continuous improvement.
Put cross-training program in place to enhance operational capabilities & career pathing.
Developed outsourcing efforts to address growth, cost and contingency planning.
Improved aesthetics, safety and productivity through application of Lean techniques.
Best Regards
Alan S Desrocher
35 Satucket Ave
East Bridgewater, MA 02333
Phone: 857.498.0727
Alan Desrocher Linkedin Profile
ALAN S DESROCHER
(857) 498-0727
a_desrocher@yahoo.com
Executive Profile
Global Supply Chain - Operations – Business Turn-around - Customer Care
Business Development – Lean Six Sigma
I am a seasoned operations veteran with a diverse background in company operations, supply chain, transportation, logistics, and general management. Prior to joining Tennessee Tool my most recent position was with Schwarzkopf Technologies / Plansee as Director of Manufacturing. There I was responsible for all strategic and tactical operations management with P&L responsibility of well over 90% of the company. This included general operations, distribution, purchasing, inbound/outbound logistics, inventory control, quality management, vendor management and customer fulfillment. Prior to joining Schwarzkopf, I held similar executive roles at Fraen and AccuRounds, specializing in operations and contract manufacturing. . I have 19 years of hands on experience with all facets of machining most types of materials with CNC and Conventional equipment. We manufactured process controls & automated systems for Nuclear, Medical, Aerospace, Oil & Gas, Paper & Pulp, Petro Chemical industries.
Key Leadership Strengths
• Operations Management
• Process Improvement
• Business Development
• Vendor Negotiations
• Configuration Management
• Customer Care
• Top Management Interaction
• Forecasting & Modeling
• Developing Pricing Models
• Expense Control
• Budget Management
• Team Building / Leadership
• Training & Coaching
• Employee Retention
• Problem Resolution
Professional Experience
Tennessee Tool & Engineering, Oak Ridge, TN
General Manager / Director of Engineering Production Machining & Assembly
(04/2008 to 04/01/2009)
Revenue Enhancement / Productivity Improvement
• Products for the Automotive Industry, Heavy Truck Industry
• Reconfigured operation software to realize maximum revenue streams
• Tripled throughput in less than 6 months and reduced overtime by over 90%
• Instituted metrics and documentation tools to capture 6 figure savings.
• Introduced Visual Manufacturing metrics to streamline estimating and planning, which tripled quoting capacity without adding staff.
• Improved margins to improve negative cash flow toward positive territory
Team Building / Leadership
• Collaborate with sales to lead business development efforts with new and existing clients. Serve as technical advisor in sales meetings, provide tours, and visit factories to uncover clients distinct business needs. Key role in increasing annual revenues by $3 Million with Automotive Customer, re-quoted all top twenty accounts to reduce loses through margin erosion and turned those into profitable accounts
Vendor Negotiations
• Manage capital purchase of lathes, milling equipment, and materials processing equipment to increase accuracy and productivity.
• Moved all but three pieces of equipment to realize profitability gains logistically. Led negotiations to capture significant discounts on $1M worth of equipment including Robots, set up an automated cell that generates over 1.2M dollars worth of revenue using one operator.
• Initiated re-installation of 100 new light fixtures to improve lighting by 50%, painted all walls and floors using in-house staff, resulting in cost recovery due to visual enhancements
Brooks Automation, Chelmsford, MA
Global Commodity Manager- Temporary Position (07/2007 to 11/2007)
Defined a global sourcing strategy for suppliers that: Minimized the total costs globally (including logistics, inventory carrying,
customs/duties, etc. as applicable); leveraged global mechanical spend of over 140M for a 700M Corporation
• Products for the Semi-conductor Industry
• Created Strategic Plans to reduce 100 existing machining suppliers down to less then 20
• Created Evaluation Tools and used them on over 25 “Key” Suppliers Nationally in less then 60 days
• Executed global sourcing strategy for 5 divisions
• Qualified new suppliers and parts as needed, with support of Supplier Quality Engineers
• Ensured uninterrupted supply of product to all business units; Fulfilled global business unit requirements (cost, quality, on-time
• delivery, lead-time/ inventory levels)
• Developed negotiation planners, participated in and/or lead negotiations and execute agreements.
• Ensured compliance both internally and externally within the supply base regarding fulfillment of agreement responsibilities
• and expectations.
• Lead and manage supplier transitions (ramp-downs; ramp-ups).
SCHWARZKOPF TECHNOLOGIES, Franklin, MA (05/2004 to 12/2006)
Director of Manufacturing
Planned and developed departments from the ground up. Managed large-scale projects, operations, facilities, engineering, estimating, planning, quality, purchasing, programming and tooling as well as R & D projects for a 70 million dollar corporation.
Revenue Enhancement / Productivity Improvement
• Products for the Medical, Semi-conductor, Lighting, Furnace, and Heavy Metals Industries as well as Aerospace & Defense, Pressure Vessels and Furnace Equipment
• Industries
• Doubled throughput in less than one year and reduced overtime by over 34% using SAP and “Visual” techniques
• Instituted “Lean” metrics and documentation tools to capture $1M savings for one client alone in less then 16 weeks
• Introduced Visual Manufacturing metrics to streamline estimating and planning, which doubled quoting capacity without adding staff.
Team Building / Leadership
• Provided leadership in turning around Hot Zone business with consistent history of late deliveries to deliver seven on-time within a five week period.
• Introduced Tooling University to support performance measurement and training assessment goals.
• Instituted Employee of Month Award to recognize improvement ideas and outstanding performance
Customer Care
• Collaborated with sales to lead business development efforts with new and existing clients. Serve as technical advisor in sales meetings, provide tours, and visit factories to uncover clients distinct business needs. Key role in increasing annual revenues from $ 50,000 to $ 7Mil for one customer alone.
Vendor Negotiations
• Manage capital purchase of lathes, milling equipment, and materials processing equipment to increase accuracy and productivity. Led negotiations to capture significant discounts on $5M worth of equipment, including $135K savings on Water jet Machine that improved throughput by 40%.
• Initiated installation of 200 new light fixtures to reduce lighting bill by 50% and capture estimated $60K savings.
Production Manager
Planned and developed departments from the ground up. Managed Team Leaders and grew them into Supervisors, trained them in “Lean Manufacturing” methods, Kaizen events, Poke Yoking and process improvents.
Operations Management
• Directed production operations, quality processes, and technical support with P&L responsibility for precision machine shop providing contract manufacturing and engineer-to-order.
• Managed annual payroll of $2.7M and over 75 labor resources within multi-shift machine and fabrication shop with over 200 pieces of C.N.C. and manual equipment, lathes, millers, EDM’s, stamping, punching, bending equipment
Configuration Management
• Managed transition from ISO 9000/2001 to AS 9100 to become "Flight Certified." Audited and refined procedures and created over 400 supporting documents.
• Oversaw successful transition towards CAD/CAM integration with CAM and SPC software implementation.
Expense Control
• Increased fabrication profitability from -37% to 27% and machining profitability from 17% to 25%.
• Decreased 275% over capacity with 14-20 week lead-time to two-four weeks to align with sales projections.
• Increased on-time delivery rate from 48% to 90% and reduced late jobs from 675 to 65.
Revenue Enhancement / Productivity Improvement
• Created cellular communication boards to capture and route unplanned software variances to planning department.
FRAEN MACHINING CORPORATION, Woburn, MA
Consultant - Woburn and Loudon Tennessee Divisions (8/2003 to 5/2004)
Directed production operations, purchasing, inventory management, and technical support with P&L responsibility for Precision Swiss Screw Machine Shop. Managed 70 labor resources operating over 220 pieces of Cam Swiss equipment and 35 pieces of C.N.C. equipment.
Revenue Enhancement / Productivity Improvement
• Products for the Medical, Semi-conductor and Automotive Industries
• Doubled throughput from $500,000 to over $1M per month, which consisted of 20 to 90 million parts while reducing overtime by 30%.
• Increased on-time delivery rate from 37% to 91% and reduced late jobs from 275 to 12 within six months.
• Identified and routed all finished goods, WIP, and raw material without live orders attached through sales to capture over $250K in lost revenue.
• Reduced raw material inventory 16% and finished goods 25%.
Operations Management
• Integrated operations management strategies to perform Kan-ban builds for 50% of customer base as well as report cycle time/variation and document process flow without operational software.
• Instituted system to expedite Kanban turnaround from four-five days to 24 hours or less.
• Implemented vendor-based activity and daily shipment monitoring systems to expedite work and capture any shortages or system errors.
• Oversaw Subcontract Vendor Management, including assessment of supplier capabilities, pricing models, design review process, manufacturing services and process flow, documentation, and deliverables to build product.
BCAR, Boston Centerless & AccuRounds Woburn & Avon MA (12/1997 to 8/2003)
Project Manager - AccuRounds Division Oversaw contract management, government procurement, technical support, and system implementation for AccuRounds division. Increased customer focus and contact to strengthen corporate position and market share.
Revenue Enhancement
• Products for the Medical, Semi-conductor, Printing, as well as Aerospace & Defense Industries
• Develop internal electronic commerce program, which involved registration with government agencies, creation of centralized database for sales, and evaluation of First Index, Dibbs, and other electronic quoting opportunities.
• Planned and managed initiatives that increased sales with four of company’s largest customers by $475K. Semi-conductor business increased 34%, automotive 161%, fab assembly 86%, and environmental control 684%.
• Experienced only 3% loss in print business during period when most shops were forced to close. Successfully sustained position with customer experiencing 47% drop in business.
• Customer Care
• Developed solicitation and procurement procedures, which included corporate requirements on doing business with government, Lockheed Martin, Boeing, NASA, and DSCC.
Manufacturing Manager - AccuRounds Division
Directed all contract manufacturing operations and technical support with P&L responsibility for Precision Swiss Screw machine shop using Lilly Visual Manufacturing Software and Lean Manufacturing techniques. Oversaw 21 staff resources operating 200 pieces of equipment and producing 600 to 700 monthly work orders, which averaged to 5,500 to 6,500 operations.
• Led continuous development, implementation, and refinement of systems to strengthen operations.
• Established operations strategies and benchmarks to reduce scrap to .06% and achieve 95% on-time delivery rate, which resulted
in customer accolades
• Instituted machine maintenance and employee training schedules.
• Implemented S.P.I system to achieve metrics through improved accountability, communication, and efficiencies.
• Developed system to expedite Kan-bans turnaround from four to five days to 24 hours. Earned awards from largest customer
• three consecutive years for achieving Kan-ban requirements for 100% on-time delivery on unknown delivery requests. Set
• delivery requirements for remaining 50% of operations to achieve top performance accolades from customers.
• Evaluated operator productivity and instituted cellular environment company-wide to optimize productivity.
FOXBORO COMPANY, Foxboro MA (12/1978 to 8/1997)
• Products for the Medical, Semi-conductor, Gas, Paper & Pulp, Oil Production Industries as well as Aerospace & Defense
The largest producers of instruments and process control systems in the country in its time, this included one of the most comprehensive machine, fabrication and assembly factories of its era. The company promoted the Toyota Production System for my entire career, Six Sigma Black Belt Candidate participating in manufacturing initiatives required to remain competitive in changing marketplace.
Wore many hats and held many positions from Journeyman Machinist, Toolmaker, Technician, Team Leader, and to Group Leader
Spent many years programming, setting up and running almost every major piece of C.N.C. and Conventional machine shop equipment imaginable, lathes, millers, EDM’s, stamping, punching, bending equipment, Jig borers
• Suggested capital equipment purchases
• Worked on research and development projects
• Trained in process control utilizing clear, concise and controlled documentation.
• Led continuous development, implementation, and refinement of systems to strengthen operations.
• Developed new techniques to “Lean” out old processes using “State of the Art” equipment
• Played many roles in reducing floor space usage and project flow
• Introduced new processes to fellow employees, trained and evaluated projects
Education
Villanova University: Lean Certificate, Green Belt Certification, Black Belt Certification in process
Massachusetts College of Art: Bachelors Degree in progress
Certification & Professional development
APS of Lilly Software “Visual Manufacturing”, T.C.A. training in World Class Manufacturing,
K.E.C. Consulting: The Medical Device Quality Systems Regulation and FDA/GMP,
K B Associates Supervisory Skill Training and Process Flow Management.
Graduate of American Society for Quality Control: Effective Presentations.
SAP, E2 Shoptech, JDE, Visual Manufacturing, Vantage, Job Boss and Microsoft Office formal training. AutoCAD Autodesk Inventor, SolidWorks, Part Maker, SME and AMA memberships.
Supplier Awards Semi-Conductor
Winner of the South Shore Chamber of Commerce Sam Walton Business Leader Award
DMAIC,DMADV, 5S, JIT, TQC,TQM,TPM, OEE, GMP, 6 Sigma, Kaizen, Kan-ban, SMED, SPC, APS, MRP, SIPOC, and ITAR
