David McGan

53 Dorsey Street

Corydon, KY  42406


Phone: 270-533-6415

Cell:  270-823-2831


Objective:  seeking win/win opportunities to use my highly-developed application skills in the areas of Continual Improvement and Quality Optimization , by working with companies in their efforts to improve Quality, Efficiency, Productivity, and Cost.


Ø       Areas of Expertise


·       Lean Management Methods and Tools

o        5S / Visual Control

o        Standard Work

o        Value Stream Mapping

o        Flow

o        Pull / Kanban Systems

o        SMED (Quick Changeover)

o        Poka Yoke (Error Proofing)

o        Ergonomics

o        Kaizen Workshop Facilitation

o        Simulation Development / Delivery

o        Problem-Solving



·       High Pressure Die Casting and Related Processes

o        Process Optimization

o        Process Problem Solving

o        Casting Defects Solutions

o        Die Cast Alloy Metallurgy

o        Automotive Quality Requirements

o        Safety


·       Quality Systems

o        Quality System Development

o        Quality System Auditing

o        ISO 9000 / TS16949 Quality Systems Requirements

o        APQP, FMEA

o        SPC

o        Problem Solving

o        Customer Satisfaction

o        Supplier Management


·       Proficient with Microsoft Office tools




Ø       Experience


2008 – Present:  Owner, McGan Business Solutions, Corydon, Kentucky


·       Principal consultant

o        Advise and support clients in education, training, and implementation of Lean Manufacturing (TPS) and/or Quality System improvement methods to achieve lower cost and improved efficiencies.


1972 – 2008:  Gibbs Die Casting Corporation, Henderson, Kentucky


·       Corporate Quality Systems Manager (1998 – 2008)

o        Continued responsibility, as a member of the company leadership team, for maintenance and enhancement of the Gibbs Quality System.

o        Worked in close cooperation with Process Engineering teams to utilize experience in die casting process for process improvements and to effectively solve casting-related problems.

o        Successfully transitioned the QS9000-compliant quality system to the upgraded TS16949 Quality System requirements.

o        Managed a staff of 5 direct reports to effectively carry out Quality System and Training needs.

o        Worked closely with Gibbs IT staff to brainstorm and exploit computerized / electronic enhancement document control, process monitoring methods.

o        Developed Non-Destructive Testing capabilities by equipping plants with real-time x-ray equipment and developing training program for operators, resulting in testing-related scrap reductions.

o        Expanded implementation of effective Lean methodologies, through development of Lean Training programs and numerous kaizen workshop activities.

o        International Experience

·       Traveled globally to South Korea, Brazil and Hungary, as Gibbs expanded to overseas locations.  Consulted regularly with Gibbs brownfield locations in Munmak, South Korea, and Contagem, Brazil, a greenfield operation in Restag, Hungary, and the South Texas facility in Harlingen, Texas.

·       Effectively communicating with multiple cultures through on-going support of all global locations in Lean methodologies, including development and delivery of training programs and simulation activities to enhance understanding of Lean principles.


·       Manufacturing Quality Control Manager (1987- 1998)

o        Successfully formalized the Quality program at Gibbs, resulting in achievement of customer quality program certifications, including Ford “Q1,” GM “Targets for Excellence,” and Chrysler “Pentastar.”

o        Regularly traveled to customer locations, serving as primary customer liaison for product improvement or problem-solving activities.

o        Chief architect of formally defined Quality System to meet new joint customer quality requirement QS9000.  Successfully worked to research and select third party registrar (UL Registrars) for certification.  Achieved QS9000 registration April 1998.

o        Performed regular internal audits to identify improvement opportunities which resulted in continual maintenance of the QS9000 certification.

o        Served as the Gibbs point person to work closely with the “Toyota Supplier Support Center” in formal program to learn principles of the “Toyota Production System” (TPS) (1990-1993).  During this time, developed extensive knowledge of Lean / TPS methodologies.

·       Other Roles (1972-1987)

o        Created, directed,and maintained formal Safety and Environmental processes to meet governmental and industry requirements.  Consistently resulted in incident rates below industry standards.

o        Developed and operated wet chemistry laboratory to monitor and control process chemistry.

o        Established and operated metallurgical laboratory to ensure continuing quality of raw materials.

o        Developed formal supplier requirements for raw material quality.

o        Identified and coordinated training with external resources, as needed, to fulfill the company’s training objectives.

o        Effectively utilized writing and technical skills to write, edit and publish in-house newsletter, technical bulletins, and formal training materials to meet training needs.


Ø       Associations


·       Bluegrass Automotive Manufacturers Association (BAMA) – (1992-2008)

o        Chairman of BAMA Region 6 (2006-2007)

o        Presenter, “TPS for Leaders” workshop, at BAMA Learning Conference (2006)

o        Active lead role in numerous on-site member-company TPS workshops (2000-2008)

o         “Built-in Quality” presentation at BAMA National Meeting (1996)

·       Honda Lean Network (2007-2008)

·       American Society for Quality (since 1986)

o        Scholarship Committee Chair (2009-2010)

o        Placement Chair (2010)

·       North American Die Casting Association (NADCA)

·       Board of Directors, Henderson-Henderson County Chamber of Commerce (2007-2010)

·       Chairman of Henderson Chamber’s “Taking Care of Business” Committee (since 2009)

·       Chairman, Board of Directors, Gibbs Aluminum Federal Credit Union (since 1996)


Ø       Education & Training


·       Bachelor of Science Degree – Southern Illinois University, Carbondale, IL

·       Ohio State “Center of Excellence” Lean Auditor (2007)

·       TPS for Leaders (2005)

·       RAB Lead Auditor ISO 9000 / TS16949 with Core Tools (2004)

·       Proficient with Microsoft Office Suite, including Word, Excel, Powerpoint, Publisher, Outlook