Kipp A. Koonce
Granger
Summary
Strategic leader with a track record of launching manufacturing plants under budget and ahead of schedule. Expertise in managing multi-million dollar budgets while achieving notable cost reductions and enhancing operational efficiency. Proven success in guiding teams to exceed performance metrics in fast-paced, high-pressure settings.
Overview
32
32
years of professional experience
Work History
Director Of Operations
Resia Manufacturing LLC
Fairburn
2023.11 - Current
- Lead a cross functional, collaborative team tasked with launching a greenfield plant in the modular construction industry.
- Plant launch timing: 6 months (27 wks.) from empty warehouse to producing saleable units (bathroom & kitchen PODs)
- Tasked with managing tooling/equipment integrators and $18M CAPEX budget.
- Installation delivered on schedule at 17% under budget.
- Helped to develop and manage a $10M annual operating budget.
- Responsible for guiding, developing, and maintaining steady state business strategy (PSQRC)
- 255K sq ft facility, 90 salary and hourly employees (Semi and Fully Automated Cells + Manual Assy Lines)
- 2024 to 2025 Cost Reductions and Efficiency Gains
- Reduced Labor by 43% to match demand
- Reduced G&A Expenses by 21% and OOE by 36%
- Eliminated unscheduled overtime (OT)
- Reduced outbound shipping costs by 25%
- 100% on time deliveries
General Manager
Photon Automation Inc.
Indianapolis
2020.06 - 2023.11
- Lead a cross functional team involving innovative laser welding technology in the Energy Storage System (ESS) sector.
- Collaborated with start-up Electric Vehicle (EV) and Grid Storage companies to quickly react to rising demand.
- Helped oversee large machine tool integration projects from $1M - $53M, including complete assembly lines.
- KPI’s related to performance milestones: Performance, Time, Quality, and Cost metrics based on milestone achievement
- Helped to oversee daily operations of a 225K sq. ft. facility including 65 salary and hourly employees.
- Tasked with steering a small, niche business through rapid, triple digit growth.
- Responsible for running day-to-day operations and guiding general business strategy.
- Oversee strategic hiring, tracking cash flow, and setting sales goals for the team.
- Developing key performance goals and managing the performance of staff
- Creating and implementing strategies for rapid business growth
- Helped develop internal processes for better productivity.
Plant Manager
Rivian Automotive LLC
Normal
2017.11 - 2020.06
- Helped oversee commissioning of a 2.6M sq. ft. facility.
- Responsible for hourly and salary workforce planning for 6/2021 Start of Production (SOP)
- Developed EHPV template to forecast hourly staffing.
- Helped develop conveyance layout in Final Assembly
- Responsible for commissioning and managing the building including: Stamping, Body, Paint, Final Assembly, Energy Storage (Battery) & Propulsion, and Quality
- Budget: ~$1B CAPEX including conveyance and process tooling
- Project Scope: transforming a car plant into a truck plant (complete demolition of old equipment and installation of new equipment)
- Participated in vertical integration studies (Make vs. Buy) of non-traditional automotive components including 'Skateboard' Frame, Battery Frame, Energy Storage System (ESS), Propulsion, Inverter
- Helped lead a cross functional team to develop policies including but not limited to Attendance Policy, Hourly Wage Structure, Hiring Process, People Movement Policy, Apprentice Program, Lean Training (Team Based), Obeya Training, PSQRCE & 5S Training.
- Responsible for weekly Launch Readiness Meeting (Obeya): 22 segments of the company involved, including the base departments of the plant.
- Exception based report outs (red items): Scope, Status, External Dependencies, Risks, Schedule, Open Issues, Major Decisions, A3, Team Health
Assistant Plant Manager / Production Control Manager, Mercedes Benz R-Class
AM General Commercial Assembly Plant
Mishawaka
2015.10 - 2017.11
- Help oversee daily operations of a 750K sq. ft. facility including 350 UAW and 65 salary Team Members
- Responsible for the daily production schedule including customer interface.
- Responsible for plant production metrics (PSQRC)
- Responsible for implementing and maintaining the Manufacturing Operating System (MOS)
- Joint management of inbound and outbound logistics (MBUSI, W.W. Williams, Schneider National) with goal of maintaining 1.5 DOH inventory levels
Program Manager MV-1, Launch Manager (Advanced Manufacturing Engineering Specialist)
AM General Commercial Assembly Plant
Mishawaka
2012.06 - 2015.10
- Actively involved in creating Business Development Studies, including program parameters, plant modifications or new locations, estimated labor, and capital investment
- Responsible for developing business cases including relationship model and RASIC.
- Interact with customers for product and program information as well as process changes (layout, flow, equipment, etc.)
- Mobility Ventures LLC start-up and MV-1 Re-launch – 9/2013 – 10/2015
- Led initial planning meetings during asset acquisition (maintained Gantt Chart)
- Assigned to team responsible for re-engaging supply base and Engineering Service Provider (ESP)
- Participated in Bid Pack preparation and eventual ESP contract negotiation and award.
- Led MY2014 Emissions Certification
- Prepared Tail Pipe Emissions and OBD Certification applications for CARB and EPA
- Submitted automated (on-line) application for both agencies.
- Supervised and interacted with consultants to streamline process and meet program objectives (obtained certifications prior to Ship to Commerce date)
- Co-led oversight of MY2015 Emissions & Certification – resident at Westport Fuel Systems Inc, Plymouth, MI
- Participated in decision to move certification activities from Westport to Badillo Engineering
- MV1 Program Manager
GA Area Manager – GM Hummer H2 / VPG MV-1
AM General Commercial Assembly Plant
Mishawaka
2007.07 - 2012.06
- Took over GA management functions during the 2008 H2 MCE Launch
- Worked with Group Leader’s, Shift Leader, and Team Leader’s to identify key bottlenecks.
- Worked with plant IE and UAW Time Study rep to settle disputed jobs.
- Strategically added labor and re-organized GLs to stabilize production and ensure quality metrics were met.
- Developed year to year department Business Plan Deployment (BPD)
- GA consistently met performance objectives documented by monthly scorecard.
- Led GA team through final two D-Rates and eventual balance out of the H2 program (1/2009)
Plant Planner / Plant Scheduling Manager – GM Hummer H2
AM General Commercial Assembly Plant
Mishawaka
2005.06 - 2007.07
- Plant Launch Manager – MY2008 Hummer H2 Mid-Cycle Enhancement (MCE)
- Led dept. planners to ensure manufacturing readiness for capacity changes (D-Rates) & vehicle launches.
- Coordinated Operations Plans, Launch Events, Plant Capacity Changes, & Future Ops Scenarios
- Direct interface for plant coordination with GM Scheduling (MSO), Order Fulfillment, Mfg. Strategy (PET Team), & Vehicle Engineering organizations (CRDN)
- Direct interface with GM GLP Launch Team and GM counterpart.
- Led transition from PPO to plant and integrated MVB schedule with current production.
- Coordinated daily wrap-up meetings for PIT and IRT report outs per GLP Launch template during pre-production builds (PNS, PS, SOP, SORP).
- Led cross-functional AMG team to automate GM Yellow Card process to streamline PIT team problem solving.
General Assembly Shift Leader – GM Hummer H2
AM General Commercial Assembly Plant
Mishawaka
2002.07 - 2005.05
- Responsible for startup of H2 2nd Shift Launch (six months after initial launch)
- Responsible for the hourly and salary staff attendance and the daily production & quality of vehicles
- Aid in setting up and maintaining the safety standards in the production environment while ensuring all employees adhere to those standards.
- Report out daily performance numbers in the morning executive staff meeting and ensure we meet or exceed our customers’ expectations in build and quality metrics.
- Monitor the cost of the General Assembly department from scrap rate to over-the-counter crib stock purchases.
- Promote a strong team-based environment with emphasis on improving morale and responsiveness to address production needs.
General Assembly Launch Manager – GM Hummer H2
AM General Commercial Assembly Plant
Mishawaka
2001.07 - 2002.07
- Relocated to PPO (Pontiac Validation Center and Troy Tech Park) as a member of the H2 Launch Team
- Supervised a small team of 7 hourly and 4 salary during pre-production builds (IVER and VAL events)
- Worked with contractor (DSI) to define & validate the layered build through the Virtual Build Process
- Helped set up workforce needs based on the forecast of work required to build new product.
- Helped organize plant needs for tooling fixtures, line side presentation, and plant readiness.
- Directly interfaced with CAP Operator Support Center (OSC) and Simulated Work Environment (SWE)
- Led GA launch team during 1st PVB event in new assembly plant (Greenfield Site)
- Coached team on standardized work creation, implementing the latest lean standards (GMS)
Final Assembly Senior Tooling Engineer
Ford Motor Company
Atlanta
1999.01 - 2001.01
- Responsible for all tooling (non-conveyance) including Fluid Fills, Assist Devices, Synchronous Man Carriers, Torque Multi-spindle Nut Runners, Gauges, Alignment / DVT (mechanical only)
- Direct interface with Ford Corporate Integration Team
- Supervised plant project team and tooling suppliers during installation of new equipment for New Model Launch
- Final Area certified safety representative (GRASP program) including machine placards, Lock Out Tag Out procedure and skilled trades safety training and certification.
- Final Area representative for Global Six Sigma Certification
- 6 months of classroom training at Ford Dearborn Training Center
- Certified through 6 Sigma Academy LLC
- Project objective to reduce or eliminate 3-6 month in service warranty claims for Tire Vibration
- Project allowed the plant to upgrade Tire Mounter, Soaper, Matcher, and Balancer ($2.25 mil)
Trim Department Lead Production Engineer
Ford Motor Company
Atlanta
1998.01 - 1999.01
- Department Launch Leader for MY2000 D186 Launch
- Direct interface with Design Engineers and Corporate Launch Team
- Responsible for incorporating new parts and processes into existing shop.
- Responsible for developing year to year workforce rebalance package (3-5% task reduction per year)
- Direct interface with UAW Standards Representative
- Responsible for writing and managing cost savings projects including automating manual processes, synchronous man carriers, and material handling equipment ($2-5 mil/yr depending on the year)
- Responsible for 211 workstations including in-station documentation, standard time allocation (TAKT), and ergonomic solutions.
- Responsible for all Final Assembly (Trim and Chassis) on the night shift
- Final Assembly Department Lead for ISO and Delta Torque compliance
Trim Department Production Engineer
Ford Motor Company
Atlanta
1994.01 - 1997.01
- Conducted time studies to identify efficiency gaps in main and secondary production lines.
- New product line set-up for job processes during DN101 product launch
- Balanced work among employees to achieve production rate while maintaining high quality standards.
- Contributed as PDT team member to problem solving, cost reduction initiatives, and quality improvement efforts.
- 6-month temporary assignment to assist the 1998 Ford Windstar Launch in Oakville Ontario Canada
Education
Master of Science - Industrial Engineering
Purdue University School of Technology
West Lafayette, IN1992-01
Bachelor of Science Degree - Manufacturing Engineering and Production Supervision
Purdue University School of Technology
West Lafayette, IN1990-01
Skills
- Project management
- Budget management
- Cost estimation
- Cost control
- Performance metrics
- Risk mitigation
- Operational efficiency
- Process optimization
- Project launch
- Production scheduling
- Manufacturing engineering expertise
- Strategic planning
- Schedule oversight
- Fractional leadership
- Project methodologies
- Tooling integration
- Risk mitigation
- Workforce planning
- Fractional leadership solutions
- Microsoft Office and Project proficiency
- Performance analysis
- Capital spending
Additional Information
- Positive motivator and able to instill pride through positive results.
- Analytical and logical thinking problem-solver who achieves results through defining the total problem and resolves in the most cost-effective manner without sacrificing quality.
- Possesses a strong work ethic, enjoys challenges, and takes pride in exceeding expectations.
Timeline
Director Of Operations
Resia Manufacturing LLC
2023.11 - Current
General Manager
Photon Automation Inc.
2020.06 - 2023.11
Plant Manager
Rivian Automotive LLC
2017.11 - 2020.06
Assistant Plant Manager / Production Control Manager, Mercedes Benz R-Class
AM General Commercial Assembly Plant
2015.10 - 2017.11
Program Manager MV-1, Launch Manager (Advanced Manufacturing Engineering Specialist)
AM General Commercial Assembly Plant
2012.06 - 2015.10
GA Area Manager – GM Hummer H2 / VPG MV-1
AM General Commercial Assembly Plant
2007.07 - 2012.06
Plant Planner / Plant Scheduling Manager – GM Hummer H2
AM General Commercial Assembly Plant
2005.06 - 2007.07
General Assembly Shift Leader – GM Hummer H2
AM General Commercial Assembly Plant
2002.07 - 2005.05
General Assembly Launch Manager – GM Hummer H2
AM General Commercial Assembly Plant
2001.07 - 2002.07
Final Assembly Senior Tooling Engineer
Ford Motor Company
1999.01 - 2001.01
Trim Department Lead Production Engineer
Ford Motor Company
1998.01 - 1999.01
Trim Department Production Engineer
Ford Motor Company
1994.01 - 1997.01
Master of Science - Industrial Engineering
Purdue University School of Technology
Bachelor of Science Degree - Manufacturing Engineering and Production Supervision
Purdue University School of Technology