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Q&A With Michael Caldwell Sr.

(interview me)

Michael Caldwell Sr.
Executive Lean Specialist, TBM Consulting
Location: Frankfort, KY United States
Joined: Jan 26th, 2010

About (request update)

An executive-level lean champion with more than 30
years experience in manufacturing and business, Mike
Caldwell came to TBM in 2004 after successfully
implementing lean initiatives in automotive, aerospace
and electronics, and in the process industry.
Prior to joining TBM, Mike was director of Lean
Manufacturing for Collins and Aikman where he was
responsible for driving bottom-line results in eight
plants. He also served as safety and training manager
for Johnson Controls where he managed 1,000
employees.
As a consultant in lean manufacturing techniques
(Michael Caldwell Enterprises), he helped companies
such as Toyota, General Motors, Ford, Chrysler, Alcan
Aluminum and GTE Sylvania to establish and maintain
world-class processes. Tools include lean, Six Sigma,
ISO 9000, ISO 14,000 and PCDA. Mike is especially
sought after for his skill in creating and leading cultural
change.
Mike earned a Bachelor of Science degree in Industrial
Technology & Engineering from Western Kentucky
University at Bowling Green. He also studied lean
manufacturing techniques for four years at Toyota
Motor Manufacturing in Georgetown, Kentucky.
TBM Consulting Group, Inc. has been instrumental
in bringing lean business principles to the United
States, Europe and South America for more than a
decade. From its Connecticut beginnings, TBM has
branched out to include offices on three continents.
Profiled in several publications, TBM has been
credited with turning around hundreds of companies
worldwide in the manufacturing and service sectors

My Interview Question

Why is professional leadership so vital to successful companies?

Life & Professional Aspirations:

A SENIOR MANAGEMENT or STAFF LEVEL POSITION with a progressive organization, based upon proven skills at creating change, using salesmanship in its broadest sense, a passion for continuous learning and growth, and a commitment to the analytical approach to problem solving using reasoning and negotiation.

Education (request update)

High School: Shawnee in Louisville, KY class of 1973

Experience

I currently work with TBM Consulting as Executive Lean Specialist
I have 28 years of experience working in the Manufacturing and Production industry.

Executive Lean Manufacturing Specialist | TBM Consulting
From January 2004 to December 2009 • 5 year(s)
Led significant Kaizen Breakthrough events within heavy unionized and union-free manufacturing organizations. Specialized in culture change, long term sustainment and leadership development.

Director of Lean Manufacturing | Collins & Aikman
From January 2002 to December 2004 • 2 year(s)
Directed Lean Manufacturing training and protocols for eight Northern Mat, Carpet & Acoustic facilities including facilities in Ontario and Quebec, Canada. Worked closely with plant managers and Lean Champions to drive bottom line results through Kaizen activities.

Executive Lean Manufacturing Specialist | RWD Technologies
From January 1997 to December 2001 • 4 year(s)
Associated with major global consulting organization supporting Lean development within automotive Big Three. Worked directly with key management leaders in Detroit area to reduce costs and create environment of continuous learning.

Change Leader/Consultant | MCE (Michael Caldwell Enterprises)
From January 1996 to December 2001 • 5 year(s)
Trained and developed management teams and implemented World Class Manufacturing Techniques for OEMs and suppliers within automotive, electronics, and aerospace industries. Responsibilities included total communication of established protocols in ISO-9000, ISO-14000, Six Sigma, and PDCA.

Operations Manager | Plasti-Line Industries
From January 1995 to December 1996 • 1 year(s)
Managed all production and training activities for workforce of 500 hourly and 35 salaried employees at one of the largest manufacturers of mass produced commercial signage. Led organization to exceed previous record for monthly shipping dollars for 4 consecutive record-breaking months beginning in 1995.

Safety & Training Manager | Johnson Controls, Inc.
From January 1987 to December 1994 • 7 year(s)
Held increasingly responsible position with global Tier I automobile component manufacturer supplying Ford, GM, and Toyota in Lean Manufacturing, JIT environment. Completed over 24 consecutive months with no lost time accidents and managed 1,000 production employees utilizing Toyota Production System.

Facilitator/Semi-Autonomous Work Groups | Alcan Rolled Products, Inc.
From January 1979 to December 1987 • 8 year(s)
Grew from production coordinator position to set up one of the nation's first semi-autonomous work group programs within union environment. Enabled headcount reduction from 1,800 to 700 for 65% labor cost savings with simultaneous growth in both quality and production.

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Guestbook Comments

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