-  Teambuilding - Operations Optimization- Inventory Control

 - New/Retrofit Plant Construction - Warehouse Management Systems

 - Shop Floor Control - Process Control - Business Systems

 - Manufacturing Execution Systems - Quality Information Systems

Overview

Members of the Performance Operations team have many years of experience in new plant construction as well as retrofits.  Projects include new processing facilities, taking research and development processes to full scale production and automation of manual and semi-automated processes.

Executive and Management Teambuilding

Gene Kaplan has developed a practical way of getting alignment in and improving teamwork and human communications in executive and management teams.  This has been necessary so as to ensure the success of various technology project endeavors.  This responsibility typically includes:

	Developing an understanding of and typically challenging the business vision and mission
	Clarifying the vision and mission and creating a Shared Vision among the team
	Developing the human communications and teamwork of the team using modern personality and teambuilding tools
	Assisting with the professional development of the team, including additions to the team as needed
	Leading change

Projects include:

	Leading change for a 15 person management team in a mid-sized food processing company
	Unifying a multi-vendor team while developing an innovative new packaging manufacturing process
	Selection of team members and teambuilding for several new manufacturing plants

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Operations Optimization

Gene Kaplan has led client and service provider teams in optimizing manufacturing and distribution operations before, while and after implementing technology solutions.  This responsibility typically includes:

	Developing an understanding of and documenting existing workflow
	Challenging the "status quo" and working to bring operations and technology teams together
	Leading the professional development of client personnel
	Managing the change process
	Developing new non-technical operations solutions
	Leading technology teams from the user's point of view

Projects include:

	Implementing manufacturing operations changes for a large frozen foods processor
	Defining operations for a large packaging manufacturing start-up

New and Retrofit Plant Construction

Gene Kaplan has been responsible for all information, process control and data collection technologies for several new manufacturing plants as well as retrofits.  This responsibility typically includes:

	Developing IT, process control and data collection technology standards
	Creating vendor specifications and managing vendor procurement and negotiations
	Managing vendors during implementation, from design review through to checkout
	Leading in-house systems integration activities
	Developing training programs and turnover of plant systems to maintenance teams

Projects include:

	Numerous blending, aseptic processing and packaging projects for food and beverage and pharmaceutical companies
	New proprietary manufacturing process for environmentally friendly packaging product

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Inventory Control

Gene Kaplan has implemented numerous real time inventory control systems, typically using bar code technologies, in manufacturing scenarios since 1988.  Responsibilities typically include:

	Creating the vision for the system and determining feasibility
	Developing functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Leading the make/buy decision process
	Controlling vendor selection or leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

	Several food packing and processing facilities, including fruit, vegetables, meat and poultry
	Raw Materials, WIP and Finished Goods for numerous manufacturing processes, including packaging, nursery plants, electronic components, raw steel, mechanical assemblies
	Supplies for a municipal water district

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Warehouse Management Systems

Gene Kaplan has led the implementation of several comprehensive Warehouse Management Systems using bar code technologies, in manufacturing and distribution scenarios since 1988.  Responsibilities typically include:

	Creating the vision for the system and determining feasibility
	Developing functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Leading the make/buy decision process
	Controlling vendor selection or leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

Raw Materials, WIP and Finished Goods for several manufacturing processes, including prepared food products, packaging, tape and electric conduit

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Shop Floor Control

Gene Kaplan has led the implementation of several comprehensive Shop Floor Control Systems using various component tracking technologies in discrete manufacturing scenarios.  Responsibilities typically include:

	Creating the vision for the system and determining feasibility
	Developing functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Leading the make/buy decision process
	Controlling vendor selection or leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

Complete tracking and serial traceability of fiber optic components, electronic and electro-mechanical assemblies

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Process  Control

Gene Kaplan has led the implementation of numerous Process Control Systems using various industrial control technologies in discrete, batch and continuous process manufacturing scenarios.  Responsibilities typically include:

	Working with the scientists and engineers to create the process, set the control vision and determining feasibility
	Developing process and instrument diagrams, functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Controlling vendor selection and leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

	Numerous blending, processing, tank farm and routing packaging processes for food and beverage companies (>40 projects)
	Several conveyor material handling sortation systems, including luggage handling, package shipping systems
	Numerous bulk material handling processes, including soap, bakeries, plastics and mining (>20 projects)
	Numerous metal finishing and plating processes (>30 projects)
	Several vacuum laminate presses
	Various "one off" or proprietary processes, including a turbine powered water pump, special machines, various thermal processes, hydraulics, chemical processes, dryers and annealing

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Business Systems

Gene Kaplan has led the implementation of Business Systems where off the shelf products were insufficient to meet the user's requirements.  Responsibilities typically include:

	Working with executives and accounting professionals to determine the need, investigate prospective solutions and make the decision to build a custom system or modify an existing solution
	Developing various data flow and business process documentation, functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Controlling vendor selection and leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

	A complete business, inventory management and shipping system for a movie title archiving company
	A shop floor inventory control and serial number tracking system by customizing the manufacturing module of an off the shelf business systems product

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Manufacturing Execution Systems (MES)

Gene Kaplan has led the implementation of several Manufacturing Execution Systems using various industrial control technologies in discrete, batch and continuous process manufacturing scenarios.  Responsibilities typically include:

	Creating the project vision with executives and managers
	Developing functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Controlling vendor selection and leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

	A milk and ice cream process
	A large wire manufacturer
	A leading window manufacturer
	A leading electronics refurbisher

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Quality Information Management Systems

Gene Kaplan has led the implementation of several Quality Information Management Systems using information technologies.  Responsibilities typically include:

	Creating the project vision with executives, managers and lab personnel
	Developing functional requirements, storyboards and systems design products
	Determining payback, setting and controlling the project budget
	Controlling vendor selection and leading in-house systems integration
	Managing system suppliers during systems implementation

Projects include:

	A very large fruit beverage producer
	A very large writing instrument manufacturer
	A manufacturer of a new environmentally friendly packaging product

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