ZWORC Experience
Valpak
Designed and implemented company-wide Continuous Process Improvement program (CPI) based on lean, six-sigma and sustainability principles. Trained over 250 management and hourly employees on CPI techniques. Lead multiple kaizen events throughout manufacturing, Customer Service, and Sales. Designed and managed construction of new state of the art manufacturing facility. Solutions included value stream/process mapping, 5S, work cells, standard work, design of experiments, mistake proofing, total productive maintenance, quick changeover, plant layout design, and factory automation.
  • $10 million annual cost savings – due to improvements in uptime, quality/scrap and productivity.
  • Recognized as largest paper recycler in Pinellas county, perfect environmental compliance record.
  • Dramatically improved workflow, increased safety and reduced inventory.

Hertz Rental Car
Implemented the Hertz Improvement Process (HIP) in all western US Hertz rental car operations. Conducted over 50 kaizen events and led strategic planning sessions utilizing “Hoshin Kanri” and “Balanced Score Card” methodologies.
  • $8 million in annualized cost savings.
  • Resulted in 20% improvement in quality and customer satisfaction rating.
  • Integrated green solutions into HIP to cut energy costs, solid waste, and GHG emissions.

Raymond James Financial Services
Conducted office productivity study and made recommendations for job redesign efforts.
  • Eliminated bottlenecks and accommodated increased workload up to 20% without expanding staffing.

Sparton Electronics
Facilitated implementation of lean-six sigma program (FlexMOD) in three separate plants in Florida and New Mexico. Organized work cells using 5S and kan-ban systems.
  • Resulted in 50 % reduction in total business lead time.
  • 50% increase in facility manufacturing capacity.
  • 10% reduction in cost of goods sold.

Ford Motor Company
Developed Ergonomic Study and Hazard Ranking System; Conducted ergonomic job evaluations in 6 assembly facilities to prioritize jobs with high ergonomic hazard and initiate job redesign efforts; trained Ford engineers to use the methodologies developed.

Bausch and Lomb
Provided Environmental sustainability training to 30 Environmental Health and Safety staff from global manufacturing sites on four continents.

Linvatec
Ergonomic job analysis and redesign of process cells for reduced ergonomic hazards to employees.

Hewlett-Packard
Redesigned layout of Scientific Instruments Division to facilitate efficiency gains. Resulted in improved workflow, reduced costs, and facility ability to absorb future growth in staffing.

James A. Haley Veterans' Administration Hospital
Ergonomic evaluation to determine opportunities for reducing back injuries amongst nurses and orderlies via equipment, procedural, and policy changes. Implementation accomplished by Hospital engineers.

State of Kansas Department of Health and Environment
Landfill management review for Kansas Department of Health and Environment. Statistical analysis of data regarding landfill management procedures and environmentally related activities such as recycling, composting, waste segregation, etc. Final report used by KDHE to recommend changes throughout the state's landfills.

Mitsubishi Film of America, Greenville, South Carolina
Designed and implemented new production control and monitoring systems for major plant expansion. Reduced planning and scheduling cycle and aided in matching orders to in-stock items and decreased overproduction.

Masland Custom Rugs, Mobile, Alabama
Designed and implemented production order processing and tracking systems. Increased accuracy of completion dates to clients and increased utilization of production operations.