Doug O'Tool, CSSBB

Accountable for all Continuous Improvement activities at 42 worldwide manufacturing factories, including achieving over $220M of yearly gross savings. Responsible to teach, coach and apply Lean and Six Sigma methodologies across the footprint, and to attain world-class levels of safety, quality, cost and productivity. Administrator and architect of Goodyear’s Enterprise PPM. This cloud-based application allows project managers to work with detailed project tasks, resources, financials, and goals to ensure project delivery is on-time and on budget. Champion and creator of the Global Best Practice Sharing and Replication system. This system certifies Best Practices, shares them with thousands

Responsible to create and implement processes to optimize assets, improve productivity, identify abnormalities ,and decrease costs at 7 facilities in the NA Region. Developed a multi-year strategic process to analyze customer Requirements vs machine Capability and Capacity RvsCC. The process highlights bottlenecks, productivity improvements, and identifies all areas requiring capital funding.

Responsible for the implementation of Lean and Six Sigma methodologies, projects and processes at a 1.9M sqft tire facility. Managed +50 person Kaizen teams that improved asset utilization, decreased waste, improved customer satisfaction and reduced cost by $11M per year.

Responsible for the development of the continuous improvement program and implementation of industrial standards at a 180k-ft² rubber tread manufacturing facility in Social Circle, GA. Project Leader responsible for the relocation and startup of a 120k Sqft facility, reducing cost by over $6M per year. Used Statistical Process Controls and the DMAIC process to improve yield, increase run speed, and reduce change over time of a constrained Extruder. The improvements reduced the need for outside suppliers, saving an additional $1.1 M per year.

Hired as a World Class Manufacturing Manager - Piloted the CI program and applied world class standards at a 300k sqft plastic injection and painting facility. Promoted to BMW Liaison Engineer - Worked directly with the customer and coordinated all the engineering changes with BMW’s Spartanburg assembly plant. Plastic Omnium is the second largest manufacturer of automotive bumpers and fenders; it operates 110 facilities in 25 countries with over $7.2 billion of annual sales in 2017.

Responsible for the design and startup of a 188k sqft, $18M plant in Nuevo Laredo, Mexico. Analyzed equipment requirements, wrote engineering specifications, maintained blueprints, managed the acquisition and coordinated the installation of over $11M of production equipment. Completed the project three months ahead of aggressive plan, saving more than $2M in overhead and operating cost. GST is Toyota’s largest leather supplier and is a world leader in automotive seating with $700 million of sales in 2016. GST also supplies Lexus, Acura, Honda, Ford, and Chrysler.

Assigned to perform Kaizen events to reduce costs. Implemented over $600k of annualized saving in less than 9 months.