Operations & AI Leadership

I build systems that
drive results.

Operations leader who builds the cadence—real-time visibility, clear priorities, and accountable execution. I design AI systems that compress weeks of manual work into minutes and scale across entire organizations.

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What I Build

AI systems that multiply operational capacity

I design and deploy AI that eliminates manual work, connects disparate systems, and turns raw operational data into decisions—customized to the organization, scalable across every plant.

01

Real-Time Production Intelligence

Automated data capture from sensors, PLCs, and existing equipment—surfacing OEE, downtime, and quality metrics without manual entry. Systems that see every machine, every shift, in real time.

Proven: JMOS · 16 Machines · 2.8M+ Records
02

Intelligent Process Documentation

AI-generated SOPs standardized across every facility in hours, not months. Embedded troubleshooting from CMMS feedback loops. Living documents that improve with every work order.

SOPs · CMMS Integration · Continuous Learning
03

Workforce Intelligence

Automated cross-training matrices that prevent scheduling untrained operators. Voice-based defect and downtime logging that eliminates paperwork at the point of work.

Cross-Training · Voice Logging · Compliance
04

AI Agents for Reporting & Analysis

Autonomous agents that compile shift reports, surface anomalies, and deliver insightful summaries—so leaders spend time acting on data, not assembling it.

Automated Report-Outs · Daily Intelligence
05

Automated Continuous Improvement

DMAIC phases executed with minimal human intervention. AI identifies constraints, proposes countermeasures, and tracks implementation—systematic improvement at machine speed.

DMAIC Automation · Root Cause · SPC
06

Workflow & System Integration

Custom AI that connects with existing ERP, CMMS, and quality systems. Reduces indirect labor, eliminates human error in data transfer, and creates closed-loop feedback across operations.

100% Customizable · ERP · CMMS · Quality
10–100×
Efficiency Multiplier
Hours,
not months
SOP Standardization
100%
Customizable to Any System
Zero
Manual Reports Required

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 8 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.

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.

Financial Forecaster

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

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.

Production Swim Lane / Line Balance

Horizontal swim lane visualization mapping actual cycle times across sequential process steps. Identifies bottleneck stations relative to takt time for targeted line balancing and throughput improvement.

Station Cycle Time vs Takt Time
Under Takt
At Takt (±5%)
Over Takt (Bottleneck)
Takt Time
AI Insights Decision Engine

Predictive analytics pipeline that surfaces equipment health insights from vibration, temperature, and SPC data—translating sensor signals into maintenance decisions before failures occur.

AI Insight — Priority Alert
Mar 17, 2026 · 06:42 AM
Cable 2 vibration amplitude increased 23% over 72 hours. Frequency spectrum shift consistent with inner-race bearing degradation. Bearing failure probability: 87% within 14 days. Estimated unplanned downtime cost if failure occurs: $18,400.
Vibration Trend — 7 Day
Decision Taken
Bearing replacement scheduled during planned maintenance window (Mar 21). Parts pre-staged from inventory. Estimated repair: 2.5 hours vs 8+ hours unplanned. Production impact: zero.
$18.4K Downtime Avoided
5.5 hrs Time Saved
100% OEE Protected
SOP Standardization Program

Redesigned standard operating procedures from inconsistent tribal-knowledge documents into structured, version-controlled formats with embedded troubleshooting trees and direct CMMS integration.

Before
SOP-114: Press Startup
Last updated: Jan 2019
1. Turn on main power
2. Check oil level (see Jim if low)
3. Wait for pressure to build up
4. Run a test piece
[No troubleshooting steps]
[No safety lockout reference]
[Format: Word doc, uncontrolled copy]
After
SOP-114 Rev.C: Press Startup
1
Verify LOTO clearance per SAFE-201
2
Confirm hydraulic oil level ≥ 75% on sight glass
3
Energize main → wait for 1800 PSI (≤45 sec)
4
Run first article → log in CMMS WO
Rev C · Mar 2026 Owner: N. Kadunce Review: Annual
Production Loss Waterfall

Interactive waterfall visualization cascading from theoretical capacity to actual output, quantifying each loss category. Enables rapid identification of the highest-impact improvement opportunities across availability, performance, and quality.

Process Improvement 2 projects
Six Sigma Black Belt Project

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

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.

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.

  • Own full P&L for a high-volume manufacturing site, driving 36.7% output increase within first year through operational cadence redesign and data-driven target setting
  • Built a financial forecasting model that improved operating net income visibility and reduced month-end variance, enabling faster executive decision-making
  • Designed and installed a cross-functional daily management system aligning production, maintenance, quality, and safety—eliminating siloed reporting and accelerating issue resolution
  • Led strategic shift from reactive to planned maintenance through CMMS implementation, reducing unplanned downtime and extending asset life across all critical equipment
  • Developed and coached front-line leadership through structured Supervisor Standard Work, raising accountability, reducing turnover, and building a pipeline for internal promotion
  • Established quality governance framework with automated SPC, material traceability, and quarantine controls—strengthening customer confidence and reducing cost of poor quality
  • Architecting enterprise-wide AI deployment strategy—standardizing SOPs across facilities, automating DMAIC workflows, and building AI agents that eliminate manual reporting across the organization
JMOS AI Agents CMMS Workflow Automation
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 Black Belt
Six Sigma Global Institute (SSGI)
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
Ask About Nicholas
Ask me anything about Nicholas Kadunce—his leadership approach, technical capabilities, career impact, or what he brings to an executive operations role.