Frédéric Rudondy

COLEOS - Constraints & Lean Operating System - allows companies to make real changes in their bottom line results using intuitive managemen technics inspired by Lean & Synchronous management.

Five steps process:

- STRATEGY: Complete flow analysis of th business to find contraints and defeine the value chain
- MANAGEMENT: Management change to exploit the constraints and the value added operations
- CHANGE: Processes modification to subordinate all the operations to the contraints and put in flow
-PROJECT: New methods implementation to elevate the constraints and respon to the demand
- BEHAVIOUR: Repeat cycle to achieve perfection

Sector: Organization and Strategy

Member of France Management Team, reporting to CEO. Leading a team of six senior managers (including Finance, HR, Operations & Sales) responsible for restructuring the 3 “Comfort Foam” business units (€35M). Manage the closure of two sites, develop strategic objectives and launch key initiatives for the third plant to become a World Class Manufacturing facility. Manage $2M budget.

Achievements:
• Improve the cumulative EBITDA by 55% with a payback of 1.5 years.
• Improve customer satisfaction and marketing by centralising production in one plant.
• Improve Asset Turn and decrease Working Capital by 60%

Sector: Plastics

Responsible for two business units (€7.5M and €6.2M) which produce & transform PU foam for the Furniture & Bedding industry

Achievements:
• Improve Trading Cash Flow by over 40% above 2005 budget by implementing stock, synchronous and lean management
• Reduce Working Capital by 54% compared to 2005 budget
• Achieve significant results in HSE: plant record achieved between 2004 and 2005 for the number of days without a Lost Time Accident

Sector: Plastics

Responsible for leading the Exide’s customer-focused Excellence Lean Leadership project in Nanterre plant (200 employees) to improve and control processes meeting customer requirements and delivering productivity gains in Operations.

Achievements:
• Improve operations processes enabling lead time reduction from 20 days to 12 days using Value Stream Mapping tools and changing the planning procedures
• Reduce stock from 13 days to 9 days using a Kanban system from raw materials to semi-finished products and “Takt time – Standard work” method at the finishing line as well as SMED.
• Improve quality from 10000 ppm to 3000 ppm non-conformance rate by stopping the line when a problem occurs and using problem solving methods (5 why’s, Fish bone diagram) as well extensive QCPC done by the operators on the line.
• Awarded Exide’s Excell Silver status

Sector: Automobile

Work with Global Sales organization, Production Planning and Operations Management at all Timet sites (3 in the US, 2 in the UK and 1 in France) to establish a melting and raw materials operating plan which balances supply and demand in concert with global Timet operating and cost objectives
Participate and take leadership role as required in Synchronous Manufacturing / Theory of Constraint activities relating to inter-plant material flow

Achievements
• Project manager for the overall scheduling system which improved the information flow and decreased the lead time between ingots and finished products (from 5-6 weeks to 3-4 weeks)
• Develop a common overall real time planning
• Increase scrap incorporation rate by 20% using Supply Chain Management methods.

Sector: Metallurgy

Responsible for the raw material shop floor (16 employees) and the production control office (6 employees).

Achievements
• Manage the shop-floor improvement project (€1M) with new products flow and new automatic alloy weighing machine.
• Implement a new ERP system in preparation to the overall SAP deployment.
• Decrease rejection rate at the X-ray scrap line by 50% using statistical process control.

Manage both the production control office (3 employees) and the technical improvement office (5 employees).

Achievements
• Reduce WIP and especially intermediate stocks by 90% using Drum-Buffer-Rope method.
• Improve the Bill Of Material and the Routing for forged products.

Sector: Metallurgy