Chad Timothy Boucher

Engaged as the site lead for film and plastics manufacturer transformation, including implementing improved performance management systems using Lean tools, KPIs, and project identification through root cause corrective action (RCCA). I also implemented direct/indirect labor (DL/IDL) headcount reduction—improving OEE from 65% to 83% and gaining $5 million in annual savings.

Served as the engagement leader, transforming a mining equipment manufacturer's supply chain after a heavy equipment manufacturer acquired it. The transformation resulted in a reduction in inventory by 25%, or $36 million, and the critical path supply chain response time by 75%.

Key improvement activities included inventory segmentation, determination of inventory replenishment methods, and reduction of supplier response time via collaboration with the top 25 suppliers among 300, which included the following:

• Contract renegotiations.
• On-hand no-demand inventory identification, root cause analysis, and parts alternate uses.
• Material synchronization in conjunction with production pull signals, manufacturing cellular design, and assembly design for manufacturability.

Supplier collaboration was a cross-functional approach with commodity and site buyers, site production planners, site logistic planning analysts, and supplier representatives.

Directed a Lean transformation project for a heavy equipment manufacturer, decreasing defects in assembly operations by 75%, total defects in value stream by 50%, and work-in-progress inventory by 30%. The initial $200,000 project success led to a $1.5 million extension.