Jim Athon
Executive Consultant

Select Project Experience:

In 2009, BAE Systems initiated a national continuous improvement program based out of York, PA. Jim assisted them by providing training, coaching and project implementation for over 150 engineers and managers. He coached and helped execute a variety of projects including Defect Reductions, Line Capacity Increases, Material Handling Improvements and Reduction in Lead Time and Inventories. The Initiative was very successful, and the first wave of Advanced Practitioners alone generated a combined documented savings of $2.2 million

In 2010 Tyson Foods New Holland, PA used Jim to help them develop a Lean Six Sigma Improvement initiative by providing Champion and BlackBelt training and coaching. Jim provided training, coaching and project implementation for 24 engineers and line managers in two separate waves of training. The projects included Sanitation Efficiency Improvements, Defect Reductions, Line Capacity Increases, and Reduction of Environmental Waste. As a result, the average participants project value exceeded $150k each.

In 2011, Jim was asked to assists a PEX extrusion plant in St Louis, MO with their Scrap Reduction and Material Variance Reduction projects, which had shown only marginal improvement over the preceding 12 months. Jim conducted comprehensive Multiple Regression Analysis and Designed Experiments (2k and RSM) on the pipe extrusion lines to develop optimal operating conditions, leading to a dramatic reduction of wall thickness and concentricity variation. He then developed Visual Standard Work documentation, Job Setup Instructions, and comprehensive Control Charting and Response Plans to insure continued operational success. As a result, the material scrap on a single production line dropped over 50% in 4 weeks, generating an annual savings in excess of $300k.

In 2011, Jim assisted Berwick-Offray, the worlds largest ribbon and bow manufacturer based in Berwick Pennsylvania with a Material Utilization Improvement Project. He led a team that developed and executed a comprehensive review of all material usage points, including receiving, blending, extrusion, slitting, laminating and printing. He helped the team identify and resolve numerous discrepancies in BOM's and Routings, as well as improved material utilizations through multiple changes to blending, handling and recording procedure. As a result. The project was expected to generate in excess of $500k in favorable material variances through FY2011