Michael P. Wroblewski, CPIM
Certified Six Sigma Black Belt
3944 Fred Luke Rd
Star Lake, WI 54561
Cell (208) 920-0554
ACCOMPLISHMENTS AND EXPERIENCE
DANTOTSU CONSULTING, LLC. Star Lake, WI 2015-Present
CEO and Founder
Founded consulting firm to focus on helping companies sustain continuous improvement, develop lean leadership skills, turnaround operations and align strategic initiatives.
KAIZEN INSTITUTE, Seattle, WA 2010-Present
Regional Director, North America
Kaizen Institute is the premier Global Lean / Continuous Improvement consulting, training and coaching provider with more than 350 consultants in more than 30 offices around the world. Massaki Imai is the founder of the Kaizen Institute and author of "Kaizen" and "Gemba Kaizen". Coaching and mentoring diverse clients with Lean Enterprise Development and Transformation, Organizational Culture Change, People Development, Kaizen / Continuous Improvement. Clients include Walt Disney Parks, IMF, PACCAR, Philips and others worldwide, USA, Canada, Germany, Netherlands, Singapore, India, Saudi Arabia, Portugal and Australia.
Progressive promotion from Senior Consultant and Director USA
BATESVILLE CASKET COMPANY, Batesville, Indiana 2007-2010
Leading lean initiative for all North American operations focused on continuing the lean journey through strengthening the lean culture. Batesville Casket is the leader in the North American deathcare industry and nationally recognized for achievements in operational excellence and lean, winning the 2009 Assembly Plant of the Year by Assembly Magazine, the Industry Week Top Ten Plant award for 3 different facilities and Association of Manufacturing Excellence awards both nationally and regionally.
The lean journey includes directing strategic kaizen events, process improvements and training. Projects include the creation and implementation of the “My CI” initiative to dramatically increase total employee involvement with over 5,000 employee ideas implemented, 5S program, Value Stream Mapping, process layouts, and establishing standard work. Courses taught include all the lean principles, practical problem solving, 3P, Kaizen Team Leader Training and Six Sigma Green Belt Certification Course. Lead emphasis to increase kaizen activity with over 97 events resulting in 577 kaizen implemented and 205 safety improvements in the first year.
VICTORY ALLIANCE TECHNOLOGIES, Greensburg, Indiana 2001-2007
President and Co-founder
Leading quality and lean initiatives for client companies focused on lean transformation of clients’ culture and implementation of lean tools to solve problems. The lean transformation includes directing initial lean conversion with kaizen events, process improvements and training. Projects include 5S program, SMED (quick changeover), process layouts, establishing standard work along with standard work in process and increasing the velocity of process. Courses taught include all the lean principles and a certified Six Sigma Green Belt course. One successful project resulted in a reduction in required floor space by 25% (over 3,000 sq feet), increasing velocity in manufacturing flow from 3 weeks to under 1 week, increased manufacturing capacity to bring 50 outsourced SKUs back to in-house production all without increasing manpower levels. Client companies include Reebok, Nissan, TRW, Aerofab, Pratt Corporation, Schulte Corporation, Deflect-o and Medline Industries.
MATTHEWS INTERNATIONAL, YORK CASKET, Richmond, Indiana 2001-2006
Manager of Quality and Continuous Improvement
Management responsibility for three plants focused on quality and productivity metrics with management responsibility for a quality manager, quality supervisors, engineers and inspectors. Customer service responsibility for all product quality related activities including customer point of contact, warranties and product improvements.
Using visual management tools, documented standard work, root cause analysis and DMAIC methodology, improved FPY rates in final assembly from 69% to over 96%, reduced PPM rate on finished goods audit 95% , reduced PPM rate of the number one assembly defect by 99%, reduced customer returns by 37% and improved direct labor cost savings by 40%. Completed five Black Belt projects with emphasis on common cause quality issues including one project that eliminated a product functional complaint from our customers that existed for over 7 years. Converted the corporate quality system and all quality work instructions to the ISO 9000:2000 standard using a web based intranet platform.
TELAMON CORPORATION, Indianapolis, Indiana 2000-2001
Director of Operations
Responsible for the Carmel, Indiana plant operations including electronic assembly, electronic technicians, manufacturing engineering, facilities engineering, and production control. Led corporate efforts to implement lean manufacturing principles with training and focused project teams. Established a 5-S program, converted to cell manufacturing, instituted world class manufacturing measurements, maintained ISO 9000 certification, became TL9000 certified and created visual management systems. Results from programs included improvement in quality 95% in 6 months, on time delivery in two major product lines of 100% and 97.74% while increasing the production level 275%.
WOOD-MIZER PRODUCTS, Inc. Indianapolis, Indiana 1998-2000
Responsible for the Indianapolis, Indiana manufacturing plant including metal fabrication, welding, painting, and assembly production departments. Additional areas under my leadership included tool room support, receiving, production control, and maintenance/facilities departments. Provided corporate leadership based on lean manufacturing aimed at introducing lean principles to shop floor. Using focused teams, lowered line employee turnover from 67% to less than 5%, reduced overtime percentage from 30% to 6.42%, reduced manufacturing WIP by 62%, reduced total corporate inventory by 22%, reduced manufacturing lead time from 26.1 days to 11.2 days and increased production efficiency 15.7%.
HILLENBRAND INDUSTRIES, HILL-ROM COMPANY Batesville, Indiana 1982-1998
Manufacturing Manager (1993 -1998)
Team Leader for the Assemble to Order Project and steering committee member on FDA compliance for medical devices and new product SOPs. Provide technical support for multi-plant operations in our Domestic and European operations. Additional staff responsibilities for all engineering documentation control. Participated, trained and lead an extensive number of Kaizen events covering process improvements, 3P events, Value Stream Mapping and non production process improvements.
Implemented numerous manufacturing projects at Hill-Rom achieving dramatic improvements that included designing paced assembly lines, welding set up reductions from 4 minutes to 6 seconds, completed conversion to a new MRP systems (ManmanX), ISO 9000 certification, lead time reduction from 6 days to 1 day, quality improvements from 25% to 80%, WIP reductions of 40%, floor savings of 30%, and incorporating the SMED system in quick die change reducing set up by 75%.
Production and Inventory Control Manager (1991 – 1993)
Coordinated planning, forecasting and scheduling activities for all manufacturing products. Emphasis on customer service, schedule adherence, inventory levels, one-piece flow cell design, cell design, pull techniques and productivity improvements.
Progressive promotion within the ranks of Hill-Rom holding various positions as Senior Industrial Engineer, Senior Manufacturing Engineer, Manufacturing Engineer, and Industrial Engineer. (1982 -1991)
EDUCATION and CERTIFICATION
MS in Manufacturing Management, 1994, GMI Engineering & Management Institute, Flint Michigan
BS in Production and Operations Management, 1982, Miami University, Oxford, Ohio
CPIM Certified in Production and Inventory Management 1990
Certified Six Sigma Black Belt 2003 University of Wisconsin-Milwaukee School of Eng
Extensive lean training including learning the SMED system directly under Dr. Shigeo Shingo
Co-Author of ‘Creating a Kaizen Culture”, winner of the 2015 Shingo Research and Professional Publication Award.
Active in Boy Scouts for over 20 years earning Eagle Scout Award, District Award of Merit, Vigil Honor and Silver Beaver Award. Served on BSA national staff at several National Order of the Arrow Conferences and the 1997 National Jamboree staff.
Regular regional speaker on lean leadership and principles including APICS International Conference, Reliable Plant Lean Manufacturing Conference, AME International Conference, Indizen, Summit Lean Leadership, Lean Management and Lean Design.
Founder and author of “Got Boondoggle?”, a weblog site dedicated to promoting lean manufacturing principles and six sigma quality.
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