Lean Quest

 

16541 Gothard Street
Suite 105
Huntington Beach, CA 92647
contact via e-mail
 
Tel: 714.596.3756
Fax: 714.596.3786
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Meet The Team

 

The Lean Quest Team is a group of dedicated, determined, and deeply experienced individuals who specialize in the optimization of entire supply chains for our Clients using Lean Methods while training our Clients to be self-sufficient in the implementation of Lean Methods.

Charles Emery

Managing Partner

 

Contact Chuck

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

Prior to founding Lean Quest, Chuck worked for 16 years in the Information Systems Department of Toyota where he acted as an internal consultant for the Service Parts Logistics Division. In addition to consulting, during this tenure, he was responsible for the design, development and implementation of systems that supply service parts throughout the United States and North America. Chuck has a number of major accomplishments focused on Lean Methods, with highlights including:

 

  • Managed a project to design and develop an automated warehouse control system, which provided Toyota with its most automated distribution center in the world.           

  • Managed a 50 man-year project to design and develop a warehouse management system for Toyota's largest distribution centers in the world with complete integration of Lean methods.           

  • Led efforts to create and implement department wide Education and Training Strategies, to re-skill over 500, which was a model for creating University of Toyota.           

  • Developed business and technology strategy, including integration of lean concepts, for Toyota's North American Service Parts Division.           

  • Provided supply chain solution strategies for Toyota's B2B Internet spin-off (iStarSystems).           

 

Chuck earned a Bachelor of Science in Industrial Management and Information Systems from Carnegie-Mellon University and a Masters of Business Administration from Pepperdine University.

Chuck's Clients:  Suncorp DLA

Contact Dave

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

Dave Graham

Managing Partner

 

Dave gained his Lean knowledge and experience working for 17 years at Toyota Motor Sales in the Customer Service Division implementing Lean across the aftermarket parts supply chain and distribution operations. Major responsibilities included

  • Implementation of Lean Concepts in multiple distribution center environments

  • Piloting and rolling out Lean outbound supply chain concepts from D.C. through to and including dealership operations.

  • Continuous Improvement Training & Development of divisional groups

  • Parts Center facility and operational design and launch

  • Implementation of Lean N.A. inbound supply chain from suppliers through to N.A. Parts Center

  • North American Parts Centers operations  

 

Since 2002 Dave has assisted organizations implementing Lean in their organizations.  His experience spans many industries:  automotive, defense, grocery, consumer products, heavy equipment, certification laboratories, banking; and many departments: distribution operations, store operations, sales, procurement, engineering, finance and technical support.

 

Highlights

  • Development and execution of a Lean warehouse network strategy for a $$4 billion aftermarket network.  

  • Development of training materials and training of Leadership, Lean Team, and department personnel.  

  • Lean Operations implementation resulting in productivity improvements of 15%+, space reductions of 30% - 50%, improved quality by as much as 50%, improved delivery compliance of 25% - 50%, reduced staffing by as much as 20% and improved morale by as much as 93%.

  • Value Stream continuous improvement activities resulting in value stream lead time reductions of 25% - 75%.

  • Design / delivery of workshops for the Lean Enterprise Institute and Georgia Institute of Technology.  

 

Clients include: U.S. Department of Defense Logistics Agency, Oshkosh Defense, Mopar, GM, Keystone Automotive, Meritor, Bosch, DDI, Manitou, Caterpillar, Caterpillar 3PL, Ryder, ALDI, Wahl Clipper, Suncorp, Genpact, NFM, NSF.Dave earned a Bachelor of Science in Business Administration at Western Illinois University and Masters of Business Administration in Marketing at Illinois Benedictine University.  

 

Areas of Specialization

  • Strategy Development and Deployment

  • Program & Project Mgmt.

  • Organizational Developmen

  • Continuous Improvement Trainer and Facilitator

  • Operations Design and Mgmt.

  • Storage Design

 

Contact Alan

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

Alan Noss

Managing Partner

 

Prior to founding Lean Quest, Alan worked for 13 years in the Service Parts Logistics Division of Toyota. During his tenure, he has been responsible for on going training, development, and implementation of Lean methods throughout the supply chain. Alan received top honors at 1997 North American Kaizen Conference and was selected to represent North America at 1998 Kaizen World Cup in Japan. Major projects highlights for which he was responsible included:

 

  • Managed configuration and quality control of advanced planning software for Toyota's B2B internet spin-off (iStarSystems).           

  • Led two distribution centers in the implementation of Pull System and Lean concepts to achieve operational efficiencies. Trained operations management in the development of strategies and plans for implementing lean concepts resulting in productivity gains of 25%.           

  • Implemented the first regional rollout of JIT deliveries to the dealership level. This resulted in shorter order lead times, reduced dealer inventory levels, and improved dealer operational efficiencies generating annual savings exceeding $250,000 per dealership.           

  • Managed a project to design and develop the operational procedures for a new distribution center utilizing Lean methods and an automated warehouse control system. This was accomplished in Toyota's most automated distribution center in the world. This included the integration of material handling equipment into operational processes           

  • Managed all inbound and outbound operations at a regional hub for a major freight company. Implemented short interval process scheduling to maximize operational efficiency.

Contact Luis

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

Luis E. Quinones

Senior Consultant

 

Prior to joining Lean Quest, Luis worked for over 16 years in the warehousing and distribution industry with 14 focusing on Lean Implementation. His Lean Foundation was established while at Toyota's North American Parts Operations Division for over six years. His next seven plus years were dedicated to deploying Lean at Chrysler's Mopar Distribution Network.

While at Toyota's North American Parts Operations Division, he was a key member in the network's largest Parts Distribution Center and in the planning and launch of both National Parts Centers. Highlights of his Toyota career include:

North American Parts Center Kentucky National North American Sourced Parts-Developed base assumptions and documents to support the justification, approval and implementation of the 85 million dollar 842,000sf Parts Center. Responsible for the budget, Lean Process development and launch preparation for large parts Home Positions, Storage requirements of all Home Positions, and the construction of the Parts Center.

North American Parts Center California National Japan Sourced Parts - Completed two nine-month apprenticeships with Toyota Motor Corporation's Japanese warehouse experts

 

  • Storage - Implemented 15 major storage improvement projects. Increased picking & binning productivity (LPH) by an average of 20%.           

  • JIT Warehouse Design

  • Development of JIT Inbound & Outbound Processes including Initial Design, Warehouse Lab Simulations (physical), and final Operational Flow & Design.           

 

While at Chrysler's Mopar Division, Luis was responsible for the establishment of Mopar's first Lean Model, Lean Deployment through the NAFTA Distribution Network, and establishing Mopar's only US Comingled (Mopar & Mercedes Benz) site in Orlando, Florida into the new Lean Benchmark. Highlights of his Mopar career include:

Orlando Parts Distribution Center - Transformed PDC to Lean Warehouse and Union Contract Language Benchmark that resulted in reduced delivery delay time to dealers by 92%, improved Order Cut-off to Delivery Lead Time by 37%, and increased Outbound Efficiency (LPH) by 29%

San Francisco Parts Distribution Center - Developed, launched, and stabilized Lean Pilot PDC which became Mopar's First Lean Warehouse in a UAW environment.

Mopar Lean Implementation - Developed Mopar's Lean Implementation Strategy & training materials. Managed the Lean Implementation by collaborating with all levels of the organization through Steering Committees, Launch Teams, PDC Leadership Teams, and Continuous Improvement Workshops.

Union (UAW) Relations- Established unprecedented relationship between International UAW and Senior Management resulting in Benchmark Lean Language written into the 2003 National Contract and then enhanced in the 2007 National Contract.

Luis' extensive experience developing, implementing, and managing operations that utilize Lean methods makes him superbly qualified to assist others in the development and implementation of these processes in their environment.

Contact Mike

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

Mike Spalding

Senior Consultant

 

Mike has 25 years experience in Warehousing, Distribution and Supply Chain Management. He also has IT experience as a Business Systems Analyst responsible for the design, development and implementation of Global Warehouse Management Systems, Productivity Tracking Tools, Storage Analysis and Design Programs and Supply Chain Optimization Tools. He has 10 years experience implementing Lean Principles and Processes at the Distributor and Retail level of the supply chain. 

Mercedes Benz - Business Systems Analyst. Software development and installation for MBUSA OEM Parts Network and Supply Chain. Systems integration of Warehouse Management System, Inventory Control and Transportation Solutions.

Mercedes Benz – Industrial Engineer. Responsible for all U.S. Parts Distribution Centers space utilization and process optimization as well as developing inventory control procedures to maximize fill rates and minimize carrying costs.

Chrysler LLC – Project Manager. As a member of the “Lean-Team”, Participated in launching Mopar’sfirst Lean Model Parts Distribution Center using Lean Principles. Deployed Lean Storage throughout 21 regional PDC’s and 4National PDCs. Developed Storage Analysis Tools used to Implement and maintain Lean Storage Techniques. Designed Warehouse Productivity Tracking and Reporting database integrated with WMS and used at all 26 NAFTA Locations.

Mike has also worked within retail environments, Implementing Lean inbound process flows resulting in better managed “back-room” space utilization and significantly reducing Dock-to-shelf time.

Guy Olivier

Senior Consultant

Contact Guy

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Lean Quest

16541 Gothard Street

Suite 105

Huntington Beach, CA 92647

Tel: 714.596.3756

 

Guy has spent 25 years in Lean Manufacturing and Engineering. While studying Industrial Engineering in 1984, Guy launched his career as a management trainee at Toyota and is a graduate of the "Toyota Management" program, a 3 year, full-time program with an emphasis on management grooming and TPS (Toyota Production Systems). After graduation Guy worked as a Process Engineer and later managed the Process and Mfg. Engineering departments where he excelled at managing change programs on passenger and light truck models which included Program Managing new model introductions like the Toyota Camry and Corolla. Guy also played a key role in turn-around campaigns at supplier factories acquired by Toyota, transforming "batch and queue" environments to JIT (Just-in-Time). 

Since leaving Toyota in 1991, Guy has held increasingly more senior Management positions in diverse industries that include textiles, aerospace, medical, and semiconductors. As Director of Operations in contract manufacturing and CNC machining operations, Guy established Lean supply chain solutions with market leaders like Applied Materials, Siemens Medical, and Boeing Air & Space. As Vice President of Manufacturing and Services for an emerging aerospace OEM Composite Engineering Inc, Guy developed Lean manufacturing processes and assembly lines for jet powered UAVs (Unmanned Arial Vehicles) and other missile programs for the US Air Force and Navy. During this time Guy also led the implementation of new ERP systems, achieved ISO9001, ISO13485, & AS9100 certifications and simultaneously managed multiple facilities at the P&L level. 

In 2006 Guy launched his consulting career, helping commercial and government organizations alike streamline operations, improve quality, and eliminate waste across all aspects of business. With a focus on bottom line results, Guy has applied Lean thinking beyond the manufacturing floor to administrative, HR, NPD (New Product Development), and sales and even to project based programs like ISO and EPR implementation, with great effect. Understanding the Lean change cycle and the dynamics of leadership and culture has become, and remains one of Guy's passions.