Derick Flanery

Experience

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  Design Workshop LLC

  May 2007 - May 2008

  Product Engineer

  Communicated directly with designer to engineer and design innovative furniture. Redesigned old product line to enhance attractiveness to customers. Engineered designs using AutoCAD systems. Managed production of product lines. Elevated quality control to a higher level. Determined packaging and shipping needs.

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  Linwood Furniture Inc.

  May 2008 - Mar 2012

  Assitant Plant Manager

  Coordinated, directed and planned lean manufacturing processes. Developed, evaluated and improved manufacturing methods. Documented deficiencies and problems and initiated corrective action. Managed all re-engineering of product. Programmed and ran multi-axis computer routers (CNC/EDM). Prepared cost estimates and procured equipment, materials and parts. Held quality to a high standard throughout manufacturing processes.

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  Sonoco Display & Packaging

  Feb 2014 - Mar 2020

  Packaging Development Engineer

  • Develop broad knowledge of design functionality, capabilities and costs of materials for client consumer products. Use knowledge base to design, specify, test and implement new packaging designs. Maintain contacts with current material suppliers; develop contacts for new source materials.• Coordinate design research with vendors and/or potential vendors. Design and/or develop packaging to extend product life cycle, to targets marketing objectives and/or to achieve business growth opportunities.• Ensure that new packaging designs, specifications and materials will conform to current operating methods and machinery. Develop new packaging conforming to new equipment capabilities. Test new packaging for machine capability.• Use computer aided design programs to design individual packaging components and/or to create complete packaging systems/solutions.• Use computer databases to establish component specifications, to maintain specification records and to transfer data between plant management and assigned client. Verify system compatibility. Establish specifications and acceptable limits of variation. Relay specifications to quality control, to other company facilities and to other suppliers as needed.• Use standard methods and procedures to evaluate package designs. Work with client to assess current system capabilities and to make recommendations for changes.• Coordinate any external testing sources and corporate testing programs. Design tests, monitor results, compile data and make appropriate recommendations.• Present written and oral reports and presentations to both company and client personnel for test results, project status, package development and program implementation.• Provide technical support to sales and marketing for the company and client as needed. Compile data to support sales presentations, demonstrating the effectiveness of designed packages. Show less

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  Sonoco

  Aug 2015 - Mar 2020

  Responsible for generating production standards and staffing requirements for fulfillment projects using the fulfillment labor standards system. Work closely with project engineers to determine equipment speeds and capabilities. Participate in process review meetings as a representative of fulfillment/engineering. Responsible for continually reviewing production performance against standards and effectively communicating results through verbal and written reports. Maintain labor standards in fulfillment labor standards system; perform time studies as necessary to insure the accuracy of the standards. Provide industrial engineering support to multiple plants. Show less • Responsible for the plant Continuous Improvement (CI) culture and processes.• Continually fill and move cost saving projects through the CI funnel• Conduct loss analysis based on equipment downtime tracking and losses in machine OEE.• Lead 6S events throughout the division• Facility goal of saving 1.5M in material reductions and Labor• Facilitate Kaizen and Lean Manufacturing projects aimed at generating Lean/CI techniques, cost reductions, and process performance improvements.• Maintain Lean/CI implementation schedules for assigned projects, progress updates as required, and most importantly, provide documentation that demonstrates the direct link between Lean/CI implementation and direct process improvement and Plant Operations.• Provide Lean/CI training and coaching at all levels of the Plant.• Assist Managers and individual Lean/CI Initiatives.• Support production control, material control, material planning departments in improvement projects relating to scheduling inventory management and raw material flow and tracking.• Coordinate prototype and pilot runs to address design and process feasibility concerns from a departmental aspect.• Interface with plant engineering on projects addressing staffing, manpower, time and capacity issues.• Calculate cost reductions and/or various analyses to determine optimal method• Team with the Plant Controller to document savings and profit results of CI activities.• Accountable for tracking all lean, CI Projects, and reporting progress out to plant staff.• Assist in monitoring department equipment (OEE) and interface with Maintenance department to identify maintenance, repair, PM needs and TPM• Develop value stream map for each process and each value stream family within the facility• Utilize the concepts of continuous improvement and cost reduction in the execution of the job function• Green Belt Trained. Show less

  • Industrial engineer

    Jun 2012 - Mar 2020

  • Continuous Improvement Engineer

    Aug 2015 - Aug 2016
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  Lydall

  Aug 2016 - Mar 2020

  Lean Leader

  • Acted as a change agent for leading and managing continuous improvement processes while instilling a culture of accountability.• Used lean problem-solving techniques to improve quality and eliminate waste in all areas throughout the Manufacturing areas. • Created a series of cost savings projects totaling over 2.5 million, year to date. • Led/facilitated multi-tool kaizen events to successfully improve & sustain future state process while establishing and executing follow-up action items in a timely manner. • Optimized processes to reach product quality, efficiency and process repeatability, including workplace organization (6S) and changeover reduction (SMED).o Developed standard work standards and line balancing for productivity.o Optimized work flow and cell designs for shop throughput.o Led value stream mapping exercises to determine and record business improvement areas.o Optimized and level-load inventories utilizing Kanban/Pull Systems.o Planned, executed, and managed Gemba Walk audits.o Assisted in the design of new equipment layouts, setups and timing employing Lean and Six Sigma principles. • Worked closely with Focus Factory Mangers/Shift Managers to identify improvement projects and provide technical assistance as needed. • Engaged manufacturing team in continuous improvement process to ensure all projects are identified, prioritized and implemented in a timely and effective manner.• Created measurement systems supporting lean continuous improvement activities.• Tracked and executed cost reduction for process improvements.• Communicated Lean strategy, vision and expectations.• Implemented and sustained employees training and development on lean concepts.• Supported plant quality initiatives including developing Process Failure Mode and Effects Analysis (PFMEA), Control Plans, PDCAs, and Problem Solving efforts. Show less

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  Polo Ralph Lauen

  Mar 2020 - now

  Senior Continuous Improvement Engineer