Operations & AI Leadership

I build systems that
drive results.

Operations leader who builds the cadence—real-time visibility, clear priorities, and accountable execution. I architect AI-driven production systems and deliver measurable P&L results across manufacturing environments.

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What I Build

AI-powered manufacturing intelligence

I designed and deployed JMOS—a full-stack IoT production monitoring platform that replaced manual data entry with automated intelligence across an entire plant floor.

01

Production Intelligence Platform

Full-stack system integrating real-time IoT sensor feeds from 16+ machines with automated OEE computation, intelligent downtime detection, and operator-facing classification workflows.

JMOS · Node.js · PostgreSQL · MySQL
02

Downtime Intelligence Engine

Ingests 2.8M+ sensor records, applies statistical cycle-time analysis to distinguish true downtime from normal process gaps, and surfaces Pareto-ranked root causes for targeted improvement.

2.8M+ Sensor Records
03

Best Demonstrated Rate System

AI-assisted detection of sustained operator outperformance. Auto-generates rate-change proposals with full OEE context and routes approvals to management.

Automated Proposals
04

Real-Time Data Pipeline

60-second server-side cache refresh cycles processing ~15K daily sensor readings with instant dashboard response times—no database indexing overhead.

60s Refresh Cycle
05

Automated SPC & Analytics

Real-time control charting, Pareto analysis, and trend detection enabling proactive quality interventions and focused scrap reduction.

Statistical Process Control
06

Auto-Generated Performance Reports

Daily Operations Performance Reports rendered as SVG visualizations with OEE breakdowns, downtime/defect rankings—auto-distributed to stakeholders.

Daily Automation
16
Machines Automated
2.8M+
Sensor Records
15K
Daily Readings
60s
Refresh Cycle

Impact

Results that speak.

0
Output Increase
0
BESS Production Growth
0
Rework Reduction
0
Throughput Increase
0
Downtime Reduction

Projects

Tools and systems I've built

Dashboards, tracking systems, process improvement initiatives, and strategic analysis—built to drive operational excellence.

Operational Tools 4 projects
Operations Daily Dashboard

Interactive daily operations email with real-time KPIs, downtime analysis, quality metrics, and action tracking—sent automatically each morning to plant leadership. Features in-email navigation buttons for mobile-first consumption.

VBAOutlookExcelAutomation
Automated Equipment Output Monitoring

Real-time sensor-driven production tracking with automated cycle-time capture every 30–45 seconds. Statistical process control with UCL/LCL boundaries and target rate overlays for immediate deviation detection.

IoTSPCReal-TimeAnalytics
Financial Forecaster

Data-driven forecasting tool using 3-month rolling averages to generate daily financial projections, strengthening performance and improving oversight efficiency.

VBAExcelForecastingAnalytics
Maintenance Dashboard

Asset-level analytics tracking work order volume and labor hours by maintenance type. Identifies equipment and maintenance trends to improve asset availability and reduce non-value-added effort.

VBAExcelCMMSAnalytics
Process Improvement 2 projects
Six Sigma Green Belt Project

Applied DMAIC methodology to drive measurable process improvements in manufacturing operations, with documented results from Define through Control phases.

Six SigmaDMAICProcess Improvement
Root Cause Analysis (Fishbone / Ishikawa)

Led a structured RCA workshop using fishbone methodology to investigate temperature instability in a Kr/Xe distillation tower, producing prioritized corrective actions.

RCAIshikawaProblem Solving
TEMP INSTABILITY EQUIPMENT Valve wear Heat exchanger fouling Sensor calibration drift PROCESS Feed rate variability Reboiler duty swings Reflux ratio deviation INSTRUMENTATION Thermocouple lag PID tuning mismatch MATERIALS Feed composition shifts Impurity concentration PRACTICES Shift-to-shift handoff gaps Non-standard startup sequence ENVIRONMENT Ambient temp swings Cooling water temp variation

Operating Philosophy

Complexity to execution—in six moves.

1
Instrument
Build automated data flow. If it's painful to collect, it won't scale.
2
Surface
Visualize so problems are obvious. If leadership has to dig, the system failed.
3
Prioritize
Rank by impact with Pareto and SPC. Attack the constraint, not the symptom.
4
Control
Eliminate recurrence. Process mapping, control logic, clear ownership. Controls over heroics.
5
Sustain
Build systems that self-correct. The system flags, guides, and sustains—without oversight.
6
Repeat
Cycle continuously. Each pass addresses smaller constraints and higher-order optimization.
The Outcome
Datareplaces debate
Focusreplaces chaos
Executionreplaces effort

Systems don't just improve results—they make performance repeatable.

Career

Experience

2025 — Present
Jennmar
Underground Mining & Tunneling Infrastructure
Plant Manager

I lead end-to-end operations for a high-volume manufacturing site, building disciplined data systems and operational cadence that drive predictable, scalable performance.

  • Established a real-time operations system with hour-by-hour tracking and statistical targets, increasing output by 36.7%
  • Built a next-generation forecasting model that improved operating net income performance while reducing volatility
  • Created a daily performance alignment cadence that syncs production, maintenance, and quality without manual reporting
  • Transitioned maintenance from reactive to planned with CMMS deployment, work-order discipline, and data-driven scheduling
  • Implemented systemized defect logging with automated SPC and Pareto analysis to accelerate root cause detection
  • Instituted material quarantine and traceability controls to eliminate mix-ups and reinforce quality governance
  • Automated incentive math and refined Supervisor Standard Work, boosting accountability and saving hours weekly
JMOS OEE CMMS SPC
Reports to: VP of Operations
Direct reports: Production Manager, 2 Supervisors, 2 Team Leads, 65 Technicians, 8 Material Handlers
2023 — 2025
Eos Energy Enterprises
Battery Energy Storage Systems
Operations Manager

I transformed fragmented operations into data-driven, flow-oriented manufacturing systems, aligning teams and technology to scale output and reduce losses.

  • Launched the company's first production dashboards with OEE, automated gap analysis, and KPI charts for real-time clarity
  • Shifted subassembly to one-piece flow, increasing throughput 41% and cutting defects 22%
  • Reduced downtime by 36% through structured Pareto analysis and mitigation plans
  • Implemented visual systems (Kanban, Andon) that exposed problems instantly and accelerated response
  • Grew BESS output from 0.5 to 2.2 units/day by balancing workload with Yamazumi and takt alignment
  • Cut rework 66% by driving data capture, analysis, and targeted process improvement
  • Built a new third-shift team into the highest-performing shift within one month
ScrumLeanOEEKanban
Reports to: Sr. Director of Operations
Direct reports: 11 Production Supervisors, 6 Team Leads, 240 Technicians
Quality Engineer

I engineered the quality backbone that enabled next-generation products, reduced cycle times, and anchored ISO compliance.

  • Built comprehensive quality systems for new product families, including controls and test protocols
  • Reduced testing cycles by ~60% with a high-efficiency routine that boosted throughput
  • Developed a dynamic Quality Dashboard for visual metrics and rapid decision support
  • Led internal ISO 9001 compliance activities and structured audit programs
  • Cut scrap defects 30% with targeted initiatives backed by real data
  • Eliminated documentation risk through automated quality documentation processes
ISO 9001Quality Systems
Reports to: Director of Quality
Direct reports: 6 Quality Technicians
2022 — 2023
Messer Americas
Industrial Gases
Regional Production Engineer

I drove operational excellence across multiple facilities by scaling visibility, reliability, and process discipline.

  • Led Lean Six Sigma initiatives that increased specialty gas production 15%, adding over $1M in revenue
  • Delivered 15+ improvement projects, cutting downtime by 25+ days annually
  • Standardized processes across sites to reduce lead times by ~30 days
  • Guided budget oversight and risk mitigation to align spending with strategic goals
  • Applied controls, instrumentation, and safety expertise to solve complex reliability challenges
Six SigmaOEEProcess Safety
2020 — 2022
Johnson Matthey
Clean Air Division
Shift Leader II

I drove shift-level performance and safety excellence by empowering teams with lean discipline and data clarity.

  • Led cross-functional teams to achieve >5% OEE improvement with zero recordable injuries
  • Integrated lean problem-solving into daily routines, improving flow and safety consistency
  • Cultivated a performance culture grounded in accountability, development, and continuous improvement
LeadershipLeanSafety
Process Control Engineer

I built foundational technical and analytical leadership by optimizing automated processes and reducing losses.

  • Reduced cycle time 8% and defects 4% through targeted process optimization
  • Created a risk management tool that cut downtime and variability significantly
  • Strengthened collaboration across functions, eliminating 35+ hours of annual downtime
  • Mentored technicians and fostered a data-driven culture for continuous improvement
Process ControlCIMentoring

Credentials

Certifications & Education

Lean Six Sigma Green Belt
Messer Americas
ISO 9001 Lead Auditor
Exemplar Global
Certified ScrumMaster
Scrum Alliance

B.S. Chemical Engineering · West Virginia University, 2020

Connect

Let's talk.

Open to discussing operations leadership, AI-powered manufacturing, or how data-driven systems can transform your organization.

Email
[email protected]
LinkedIn
/in/nicholaskadunce
Phone
724-996-3792
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