1. 3 Smith Street, Kitimat, BC V8C 2R4250-639-3847todd.butera@riotinto.com
Todd Joseph Butera
Profile
Lean manufacturing expert with 15 years of experience and proven track record of implementing cultural change
and delivering financial and operational results
Experience includes lean deployment both internationally and domestically, in brownfield and greenfield sites,
for Union and non-Union organizations, and across various industries and cultures
Direct experience working in the Toyota Production System and learning from Toyota experts
Experience
Mar. 2011 to Present RIO TINTO Salt Lake City, Utah
Manager of Business Improvement and A sset Management , Kitimat, British
Columbia
 Manage a teamresponsible fordeployingtheToyotaProductionSystemacross a $5.0 billion aluminum
smelting constructionprojectin NorthernBritish Columbia
 Deployed lean manufacturing principles to help drive theon time and on budgetdelivery oftheconstruction
phase oftheproject
 Responsible todrive theproblemsolvingefforts focusedon the bottleneckprocesses which impact the ramp-
up ofthe smeltertowardsfullproductionof425,000 metric tons ofmolten aluminumperyear
 Manage thedeploymentofthe integrated roadmap to ensure a sustainable transformation through leadership
developmentandemployee engagement
 Responsible forthedesignanddeploymentofthe assetmanagementstrategy across thesite
Lean / Six Sigma Director Europe, Middle East, and A frica (EMEA ), Voreppe,
France
 Led a teamofmasterblackbelts and masterlean practitioners responsible forthe deploymentofthe Toyota
ProductionSystemacrossallEMEA locations andthedeliveryofvalue throughstructuredproblemsolving
 Developed anddeployeda primary metal integrated roadmap aimed at developingleadershipcapability,
driving culturalchange,andensuring sustainable improvement
 Redesignedanddelivered a lean trainingprogrambased ondeploymentphilosophy
 Deployed a value creationexecutionacceleration process at allEMEA sites
 Designed anddeployeda leadershipdevelopment programacross allEMEA sites targetedat developing lean
leaders
Jul. 2004 to Mar. 2011 ALCOA Pittsburgh, PA
Global Lean Manufacturing Consultant , Nashville, TN, Dallas, TX
 Responsible forimplementing theAlcoa BusinessSystem(based onthe ToyotaProduction System)across
multiple company locationsand industries both internationally and domestically
 Worked directly forJohnMarushin who helpedlaunchtheToyotaSupplierSupport Center(TSSC),Toyota's
internalconsultingdivision within the UnitedStates duringhis time with Toyota
 Organized and led the first globalfocus plant eventin mining with the goalofcapturing greaterthan$1/tonin
financialresultsacrossthe Alcoa mining systemby moving alllocations towards operationalexcellence
 Designed a structuredinventorysystemto help the ClevelandCommercial Wheels Divisionmeet their
customerand financialtargets
 Designed anddeployeda “systems kaizen” programacross theAlcoarolled products division
 Responsible fordevelopinganddeploying agreedupon best practicesacross22globalsmelters

2. Regional Lean Manufacturing Consultant, Perth, A ustralia
 Redesignedanddelivered lean training programwith more focus on business case activities
 Coached the pilotteamforLean Training Centerin China
 Representedthe Asia Pacific Region in a globalinitiative toreduce energyusage by improvingheater
performance,worth $28million across 9refineries andmore than $5million in Australia
 Designed andimplemented visualfactories formajorequipment overhauls as a means to capture 77tons per
day in lost productionworth approximately $5million peryear
Apr. 2002 to Jul. 2004 DAIMLER CHRYSLER Kenosha, WI
A rea Manager (Lean Specialist)
 Led the implementation ofthe Toyota Production Systemin the greenfield 3.5Lengine plant andthe
brownfield 2.7L engine plant
 Developed anddelivered lean training
 Partnered with U.A.W.counterpartand worked closely with seniormanagement andUnion leadershipto
deploy the leanmanufacturingstrategy
 Received daily coachingfromconsultants with over50years combinedToyota operations experience
 Assisted in the designand negotiations ofa newUnion contractbased onthe languageusedin the Toyota–
General Motorsjoint venture in California
 Transformed the Kenosha facility intoa learning organization forotherChryslerlocations to visitand replicate
Apr. 2000 to Apr. 2002 TOYOTA MOTOR MANUFACTURING Buffalo, WV
A ssembly Line Group Leader
 Worked as a core memberto launch the first automatic transmission facility forToyotaoutsideofJapan
 Participated in equipment trialsin Kinuura,Japanpriorto equipmentinstallation in West Virginia
 Received direct daily coaching fromtrainers employed bythe sisterToyota plant in Japan
 Hired teammembers forthe start-up ofthe transmissionfacility
 Trained newteammembers in the fundamentals ofthe automatic transmissionandthe Toyota Production
System
 Directly supervised thirty teammembers and two teamleaders in the assembly ofthe Underdrive,Differential,
Transaxle Housing,Valve Body,and othersubcomponents fortwo styles ofautomatic transmission
 Supervisedteamthrough a production ramp-up startingat 30transmissions perdayduringproductiontrials to
800 transmissionspershiftat fullcapacity
Aug. 1996 to Apr. 2000 PARKER HANNIFIN Cleveland, OH
Manufacturing Engineer / Production Supervisor A erospace, Fort Worth, TX
 Core teammember ofthe cycle time reduction project
 Coached daily by flowmanagement consultants
 Delivered classesin lean manufacturingmethodology
 Created CQM (continuousquality manufacturing)centers forallproductiondepartments
 Redesignedtheassembly lines toaccommodate one piece flow
 Responsible forallsupervisoryandengineering functions in finalassembly area
 Appointedas warehouse andshippingprojectengineerin additionto assembly functions
Manufacturing Engineer Tube Fittings, Eaton, OH
 Implemented work cells to expedite productflowand reduceset-up times
 Contributedsavingsin excessof$300,000 to the costreduction program
 Provided assistance tothe ParkerHannifin Mexico project
 Headed a project to purchaseand installa robotic chuckerautoloader

3. Education
Aug. 1992 to May 1996
Aug. 2004 to May 2006
Miami University
Colorado Technical University
Oxford, OH
Denver, CO
Bachelor of Science in Manufacturing Engineering
Executive Masters of Business A dministration
References
References are available on request.