This resume summarizes John Petak's experience in lean manufacturing and continuous improvement over 30 years. He has extensive experience deploying lean practices like value stream mapping, 5S, standard work, and kaizen events. As a consultant, he helped clients reduce lead times, improve quality and delivery, and increase productivity. His background includes positions managing operations and training employees in lean tools and principles.

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RÉSUMÉ<br />John Petak<br />115 North Orchard Farms Avenue<br />Simpsonville, South Carolina 29681Telephone: (864) 363-0984E-Mail: jpetak@exerciselean.com<br />John Petak<br />115 North Orchard Farms Avenue, Simpsonville, South Carolina 29681<br />Telephone: (864) 363-0984 / E-Mail: john.petak@gmail.com<br />Experienced<br />Lean Manufacturing Deployment Professional<br />Profile:<br />Background encompasses extensive professional experience in the following key positions of responsibility: Consultant (Lean Manufacturing); Production Efficiency Coordinator; Manufacturing Excellence Manager; Factory Superintendent; Factory Supervisor; Production Supervisor; Manufacturing Manager; Business Unit Manager.<br />Strengths: Strong skills in Lean Manufacturing deployment; over thirty (30) years of direct supervisory and managerial experience developing high-powered cross functional-teams to eliminate wasteful practices; excellent communication/interpersonal skills; proven technical skills; strong managerial/leadership abilities (able to motivate personnel to reach desired objectives).<br />Areas of Expertise:<br />● Lean Manufacturing Deployment●Customer Satisfaction PPM (Internal/External)<br />● Benchmarking & Best Practice●Continuous Improvement through Standardization,<br />● Team Building (Driven by Seven StepKaizen and Innovation<br /> Problem Solving & Fix & Mix●High Employee Involvement/Performance <br /> Mythology)Philosophy<br />● Re-Engineering Processes●Advanced Product Quality Planning<br />● Toyota Production System (Value-Stream●Lean Enterprise Principles, Tools and Methodology<br /> Mapping, Kanban, 5S, TPM, Process●Production Efficiency Coordination<br /> Mapping, Set-Up Reduction and Single-●Manufacturing Management<br /> Piece Flow, Visual Management, and●Acquisitions/Divestitures/Joint Ventures<br /> Standard Work)●Modeling/Forecasting/Budgeting<br /> Six Sigma Green and Black Belt trained<br />Recent Selected Accomplishments:<br />Clients have included Metromont Corporation, Hubbell Lighting, GTE, Tyco Fire and Safety Products, Trust Technologies, Dynamic RDSS, Fisher Barton, Griff Paper and Film, Mayekawa USA , Integrated Power Services and Spec Fab. Corp.<br />The Kilroy Company: Currently leading Trust Technologies through lean transformation. Training production associates in Standard work, 5S, 5W and 8D problem solving, SMED, Hoshin and Value stream mapping exercises at two locations. Quality – Customer DFM reduced by 50%, Delivery 99.8%, and Cost under budget and to plan.<br />Exercise Lean LLC (Hubbell Lighting): Worked with Hubbell Lighting to reduce lead time to 15 days and improve on-time delivery to 95%. Mainland China visit to 14 vendors and assisted with “Pathways to Excellence” in two US commercial and residential lighting facilities. Introduced U shape cell design that improved productivity by 12 to 15% across six assembly lines in 3 month implementation plan.<br />Exercise Lean LLC (Metromont Corporation): Developed and conducted Value Stream Mapping workshops; conducted Waste Reduction workshops driving Best Practice into five southeastern locations; implemented 6S program including strong emphasis on safety.<br />Inergy Automotive Systems: Generated over $6 million in cost reductions through 36 months targeting waste reduction, efficiency/productivity, floor space utilization, non-production supplies, and purchased part component internal PPM; Certified Trainer for People Management Program; conducted 4-day Value Stream Mapping process on BMW X5 program identifying over 50 items for improvement with potential for $400k in savings; integrated SAP with SBOP to BMW broadcast signal for sequencing in assembly; conducted TPM and JIT/Material Flow improvement to GMT 250 program in Saltillo, Mexico facility; Cost Reduction team member for NAO in 2002 tasked with additional $5 million in cost savings through VA/VE; computer-aided cycle time reduction, facilitating Team Feasibility Events on 8 major launches in Mexico, US and Canada.<br />(Continued on next page)<br />Professional Experience:<br />●EXERCISE LEAN LLC, Simpsonville, SCMay 2007 to Present<br />Chief Excellence Consultant<br />Hubbell Lighting: Tasked with reducing lead time to 15 days (vendors), developing quality system, improving on-time delivery to 95%; teach principles, concepts and tools for Lean Manufacturing.<br />Metromont Corporation: Value stream mapping workshops; waste reduction workshops – cycle time analysis, cycle time diagrams, standard work charts and combination tables; visual management, daily tracking charts and weekly summary on set-up/changeover reduction on 5 product lines; implemented 6S program.<br />Kilroy Company: Trained 2 facilities (100 employees) in 5 Why and 8D Problem Solving, Hoshin workshops, SMED, AS9002 ISO, supplying $20 million in CNC precision machined parts to GE Gas Turbine Divisions<br />GTE – Value Stream mapping workshops<br />●FAURECIA INTERIOR SYSTEMS, Fountain Inn, SCFebruary 2005 to May 2007<br />Production Efficiency Coordinator<br />Increased production efficiency by implementing 14 tools with layered audits to ensure success; trained 450 associates in the Faurecia Excellence System; produced interior trim parts for BMW - Sport Activity Vehicle X5, and Z4 Roadster in JIT environment; conducted 14 Hoshin workshops in 10-month period, improving productivity by 15% in 2005.<br />●INERGY AUTOMOTIVE SYSTEMS, Anderson, SCJanuary 2000 to Jan 2005<br />Manufacturing Excellence Manager<br />Staff Manager responsible for all Continuous Improvement activity in $170 million fuel systems division; conducted monthly Kaizen Gemba workshop in primary and assembly product lines supplying 1.2 million fully assembled tanks to General Motors (U Van, J Car, Corvette) and BMW (E36/7 roadster, X5 SAV and Z4 roadsters); utilized extensive experience (12 years) in Toyota Production Systems Value-Stream Mapping, Kanban, 5S, TPM, Process Mapping, Set-Up Reduction and Single-Piece Flow; trained employees in all aspects of Lean principles and concepts.<br />●ALFMEIER CORPORATION, Greenville, SCJune 1997 to January 2000<br />Manager Assembly and Test<br />Responsible for daily performance to plan quality, cost and delivery of finished goods to worldwide automotive customers BMW AG and US, MBUS and AG, Volkswagen and Chrysler supply fuel management system, ORVR systems, OBD II solenoid valves, and plastic R O Valves for engine submissions.<br />Successfully transferred Daimler Benz OBDII valve production from Germany to Greenville supplying 5 product versions daily to MBUSA and MBAG.<br />Successfully launched BMW E53 fuel system modules and venture pump assembly, developing process and equipment in Rottenburg, Germany.<br />JIT scheduling in injection molding department on 150 tools to kanban pull.<br />Improved inventory turns to 24/yr in molding.<br />Trained team leaders in molding on setup reduction with 60% improvement results on 14 molding presses.<br />Successful in increasing sales from $8 million to $20 million exceeding the business plan each year and within budgeted guidelines.<br />●SPARTANBURG STEEL PRODUCTS, Spartanburg, SCJuly 1996 to June 1997<br />Factory Superintendent<br />Directed off-shift stamping and assembly department including training, staffing, pay for performance, safety, employee discipline, etc.; utilized Kaizen concepts establishing baseline and drove Continuous Improvement throughout the manufacturing process, coaching and directing 125 (18% were union employees) manufacturing associates in team concepts.<br />(Continued on back page)<br />Professional Experience:<br />●HONEYWELL’S MICRO SWITCH DIVISION, Mars Hill, NCOctober 1995 to July 1996<br />Factory Supervisor<br />Directed off-shift plastics facilitating and assembly; experienced with World Class Work Force measuring and rewarding performance based on Involvement, Empowerment, Flexibility, Responsiveness, Proficiency, Learning, Customer and Quality driven, and Teaming for 80 associates.<br />●PERFORMANCE FRICTION CORPORATION, Clover, SCSept 1994 to October 1995<br />Production Supervisor<br />Monitored all secondary operations to ensure the timely processing of manufactured parts.<br />●THE STANDARD PRODUCTS COMPANY, Spartanburg, SCAugust 1988 to August 1994<br />Manufacturing Manager <br />Managed all manufacturing functions within the Division; effective administration of company policies and employee relations; maintained effective customer relations (internal and external); scheduled monthly meetings to communicate to all associates key measurements from Quality Operating Systems Facilitator for leadership training (Development Dimensions International) within the division.<br />Developed KPI floor control systems to track and monitor daily targeted goals in manufacturing.<br />Reduced scrap by 50% in primary support and flexible extrusion and secondary operations with Kaizen core groups.<br />Planned and controlled the efficient use of manning with support from the planning and executing team.<br />Achieved highest level of OEE attainable, reaching budgeted targets of 95%.<br />Used problem-solving abilities through knowledge of statistics, quality tools, planning and implementation that provided a positive improvement on process.<br />Successfully transferred major product line from the Port Clinton, Ohio facility within 45 working days, while not jeopardizing customer requirements.<br />Maintained the lowest cost of Workers’ Compensation for all divisions.<br />Prior positions with The Standard Products Company: Business Unit Manager; Production Supervisor.<br />●THE METAL PRODUCTS COMPANY, Niles, OhioDecember 1973 to February 1988<br />Niles, Ohio<br />Assistant Superintendent of Manufacturing<br />Education:<br />BS in Industrial Engineering – Kent State University<br />Training:<br />TS 16949 – Internal Auditor 2002; FMEA – Failure Effect Mode Analysis; APQP – Advanced Quality Planning; Statistical Process Control – 7 types of control charts both attribute and variable data; 8-D Problem Solving; PDCA – Plan- Do Check- Act; A3 Report Outs; Kanban / Pull Systems; SMED – Single Minute Exchange of Dies; Kaizen System; Microsoft Word, Excel, PowerPoint, Access , Visio and Minitab, ESVM and Outlook (2007); JIT/Flow Production; Trained Facilitator for DDI – Development Dimension International interaction management skills.<br />Rath & Strong Green & Black Belt training<br />Week 1 Six Sigma Green Belt Training and 4 Week Black Belt Training Topics<br />Six Sigma Introduction <br />Six Sigma Project Definition <br />Project Selection Process <br />Six Sigma Deployment<br />Process Mapping <br />Input Prioritization Tools <br />Failure Mode Effect Analysis<br />Minitab 16 Introduction <br />Measurement Systems <br />Capability Analysis <br />Sample Size Selection<br />Statistical Process Control <br />Process Control Plan <br />Project Plan & Deliverable <br />Project Reviews <br />Week 2 Six Sigma Green Belt Training and 4 Week Black Belt Training Topics<br />Week 1 Review in Class Project <br />Advanced Graphical Analysis <br />Multi-Vari Planning<br />Variation Trees and Funneling<br />Hypothesis Testing<br />Central Limit Theorem <br />Statistical Analysis Roadmap <br />Test for Mean with t-test <br />One Way ANOVA<br />Nonmanufacturing Applications <br />Correlation and Regression<br />Multi-Vari Analysis <br />Process Control Plan <br />Project Plan & Deliverable <br />Project Reviews <br />Final Exam<br />Organizations:<br />Institute of Industrial Engineer (IIE – Chapter 247); Served as an officer as President, Vice President and Secretary for 4 years - took chapter from Bronze status to Gold status. Member of the Association of Manufacturing Excellence (AME)<br />Volunteer small business experience to Redemption Marketplace Alliance<br />