John Deere Manufacturing Overhead Reduction
Led operational efficiency initiatives reducing manufacturing overhead from $12.3M to $9.1M annually.
The Challenge
Manufacturing overhead costs of $12.3M annually were significantly impacting profitability and putting pressure on the division's financial targets. The overhead structure had grown organically over years without systematic review, resulting in redundant processes, underutilized resources, and inefficient workflows. Any cost reduction initiative needed to preserve John Deere's rigorous quality standards and maintain production output—cutting corners was not an option in an environment where product reliability directly impacts customer safety and brand reputation.
My Approach
Applied Six Sigma methodology to systematically map every overhead cost driver across the manufacturing operation, identifying root causes of waste and inefficiency rather than just symptoms. Led cross-functional teams through DMAIC (Define, Measure, Analyze, Improve, Control) cycles to develop data-driven solutions for each high-impact area. Implemented Lean manufacturing principles to streamline workflows, eliminate non-value-added steps, and optimize resource allocation. Established control mechanisms and ongoing measurement systems to ensure improvements were sustainable and didn't regress over time.
Technologies & Tools
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