Advanced Maintenance Management System (AMMS):
In the early 1980s, there wasn't any Computerized Maintenance Management System (CMMS) available on PCs. PCs were just emerging. Most of the CMMS packages were available on a Mainframe computer costing a fortune. Most companies were doing maintenance functions manually. When I worked as a Maintenance Supervisor for Kargard Industries, I realized the importance of organized maintenance management.

I developed the first PC based (CMMS), called Advanced Maintenance Management System (AMMS) which is still being marketed and used today. I was involved with every aspect of CMMS including designing, developing, testing, and marketing. There are over 1800 users worldwide. A CMMS increases the productivity of a maintenance department and thereby saving money.

As a result, CMMS awareness grew in the US. With an affordable package, more and more companies started using a CMMS. The CMMS users in US have grown from 18% in early 80s to about 80% in early 2002.

Barcode Technology:
By mid 1980s, I had a robust CMMS package called AMMS. Through a number of users I discovered an opportunity to further enhance the productivity of a CMMS. I realized the results (reports) AMMS was producing were as good only as the data entered into the system. When you are dealing with thousands of inventory parts (some part numbers being very long), the data entry process was inefficient and error prone.

I noticed Barcode technology being used in Grocery and Department stores seamlessly. I was able to apply the technology to CMMS (Equipment, PM, Work order, Inventory, and Purchasing modules). The result was enormous amount of speed, accuracy and dollar savings.

Computer-aided Vertical Storage and Retrieval System:
In the late 1980s, I was working with a manufacturer of vertical storage and retrieval system (VSRS). The problem: When you were looking for a part, you'd press a button and watch for every moving bin in front of you, stop it when you saw the part. It was a very inefficient process.

I successfully designed and developed a PC based Assembly/Kitting/Order picking system integrated with a VSRS. To retrieve a part, just enter the desired part number into the computer. The program would activate the storage system and bring appropriate carrier (location) in front of the operator.

As a result, the process became more efficient, easy for the operator and saved time and money.

Cost Estimating Software:
Most of the cost estimating process was manual for machining and metal fabricating. These component manufacturers couldn't submit proposals in a timely fashion, thereby losing business. The manual process was error prone as well. I saw need for a computerized cost estimating system.

Designed and developed a very user friendly and comprehensive manufacturing/machining cost estimating software from scratch. Involved with marketing the software worldwide.

It started saving many companies a lot of time, money and made the process error free.

Assembly Line:
In the late 1970s, John Deere was producing 160-180 tractors a day. The need was 220 tractors a day. This increased throughput meant a massive, innovative project. It would require additional space, new manufacturing and material handling technologies.

As part of this project, I managed a $36 million dollar transmission assembly line.

I successfully designed a new transmission assembly line. I directed 22 people from other departments. I was responsible for material handling, maintenance, and manufacturing aspects of the project.

The project was successfully completed with transmission capacity to support 220 tractors per day.

Hand held device:
By mid to late 90s, computers were getting smaller and smaller with more computing power.

I identified an opportunity to put plant engineering calculations on plant engineers' fingertips. I designed and developed a number of plant and manufacturing engineering calculations on hand held devices such as Palm and PDAs. These calculations cover the areas of mechanical, design, industrial, structural, hydraulics and fluid mechanics.

These programs are being used across the world. They save users time and money.

Central Tool Crib:
One of the John Deere Component Works' Facilities consisted of a 4 story building with 6 different tool cribs to support the production operation. The set up was very inefficient.

It was labor intensive, production employees had to wait in line for a long, and excessive inventories were kept in stock.. I was assigned to make this operation efficient and productive.

I came up with the "Central Tool crib" concept; i.e. all tool cribs would be consolidated into one on the second floor. We'd save tremendous amount of money in parts as consolidation eliminated the need for stocking high quantity of the same parts. Production employees didn't have to go to the tool crib for their tools and kits. Instead, with labor savings we were able to afford tool crib personnel distribute the kits to production employees.

The concept would improve labor efficiency and save material cost. The project was published in trade journals and Institute of Industrial Engineers awarded me a Free Booth at their annual conference to display the project idea.