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HILLIARD
During career have been successful in delivering a 50% setup reduction in multiple industries and achieving a 20+%
rate in process improvements
History of reducing WIP to control inventory and enable companies to operate lean
Designed shop floor control reports to trigger improvements, and trained managers to interpret reports and initiate
corrective action to improve operations
Track record of boosting productivity and cost reductions exceeding 20% of labor and realizing a return on investment
in 12 to 18 months
Wrote two chapters of the Industrial Engineering Handbook published in 2003, gave numerous presentations at
industrial engineering forums
Earned Presidents Award in 2002 - first time award had been given in 5+ years
Areas of Expertise: Lean Manufacturing Principles5S Cost Reductions WIP Reductions Methods and Process
ImprovementsProcess and Quality Troubleshooting Project Management Control Report Design Work Area
Layout Team Building Training.
An innovative leader Change Agent Productivity Improvement Expert
KEVIN W. HILLIARD
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Saved $6 million for a musical instrument manufacturing facility by reducing quality issues, modifying an
incentive program, establishing shop floor control reports and best methods. Reduced
rework by identifying and correcting problems. Created best methods and training documents. Project was the
largest in Maynards history and was achieved on time and within budget.
Led an assessment effort for a tire plant and identified a $15 million potential savings. Improvements
included a Kan Ban initiative to deliver materials when needed, process improvements regarding tire building
machines and adequate staffing. Client is currently involved in contract negotiations to implement
recommendations.
Delivered an $800,000 savings at a 100-employee carbon plant and identified another $800,000 savings that
was realized the following year. Directed a 5-person team and oversaw 5S, best methods, work measurement and
control report design. Trained 19 management personnel in performance management principles to identify areas
for improvement and take corrective action.
Slashed changeover time 50% for a plastics extruder facility. Effort resolved problem with customers
demanding smaller amounts of plastics that had triggered excessive changeover times.
Assisted supervisors in identifying deficiencies and bottlenecks in assembly lines. Action achieved a 10%
productivity improvement.
Lowered changeover time in a calendar operation for a tire plant from 22 hours to 7 hours. Client was able
to defer need for additional equipment and returned all production activities in-house.
Consulted with an electrical utility company and introduced a plan that significantly improved craftsmens
productivity. Developed benchmarks that forecast hours required to achieve specific assignments and created a
kitting method enabling special materials and tools to be kitted for each job and avoid delays.
Teamed with 2 newspaper companies and architected plans for start-up printing operations. Visited various
locations and analyzed equipment and manufacturing processes; recommended use of reliable equipment and
suggested best practices to accelerate production operations.
Spearheaded a 4-person team charged with implementing a 5S project for a bridge girder manufacturer.
Project organized the manufacturing area and tool rooms and triggered a 7% productivity increase.
Earlier career: Background included 10 years with Mine Safety Appliances; spent last 6 years as an Industrial Engineer
with focus on time study, methods, capital equipment justification, equipment layouts, fixture design, product reviews
and more. High volume manufacturing as well as low volume metal fabrication. Spent 1 year in Plant Engineering
assisting with HVAC and construction projects.