Avi Dan

An accomplished Lean Expert and Continuous Improvement Leader with over 20 years of experience in driving operational excellence, specializing in transforming manufacturing operations through Lean and Six Sigma methodologies. Known for innovative leadership style and strategic thinking, with a proven track record of revitalizing production lines, optimizing workflows, and developing high-performing teams across aerospace, industrial manufacturing, and construction industries. Expertise spans implementing Lean transformations to achieving Six Sigma Gold-level performance.

Extensive experience managing cross-functional teams, leading large-scale improvement projects, and implementing Lean systems that generate significant cost savings and performance improvements.

QA/QC and Lean Processes Manager at Airwise Inc. / Modern Niagara Inc. (2024-01 – Present)

Spearheading the transformation of the HVAC company as it shifts from an underperforming, privately owned entity to a streamlined, lean operation under Modern Niagara Inc. Tasked with transforming the fabrication shop into a Lean Center of Excellence. The shop encompasses diverse operations such as sheet metal fabrication and HVAC unit assembly, faced significant challenges including inefficiencies that led to a reactive, fire-fighting work environment resulting in delays, quality issues, and poor productivity.

Leading the implementation of a comprehensive Lean transformation that addresses inefficiencies and optimizes workflows across every facet of the operation.

QA and Lean Process Manager at Modern Niagara (Mechanical Contractor) Inc. (2021-01 – 2024-12)

Transformed a 200,000-square-foot fabrication shop into a Lean Center of Excellence. Through the application of Lean methodologies, led efforts that improved production efficiency, reduced lead times, and enhanced product quality. Integrated a new Quality Management System (QMS) aligned with Lean principles, resulting in significant reduction in defects and waste, and improving customer satisfaction.

Transformation also included recertification of key industry certifications, such as TSSA, CWB, and CSA A660.

Continuous Improvement, Quality AS9100, and Lean Leader at AAA Canada Aerospace, Ontario (2016-01 – 2021-12)

• Led the maintenance and enhancement of the AS9100 Quality Management System (QMS) across multiple aerospace production sites, including Bombardier and Collins Aerospace.
• Drove operational efficiency improvements through Lean and Six Sigma methodologies, streamlining processes and enhancing product delivery.

Continuous Improvement Manager at Celestica & Honeywell Aerospace Canada Inc. (1998-01 – 2016-12)

Spearheaded multiple Lean transformations across production lines for sensors, flow systems, and aerospace components. Notable achievements include leading the transformation of the M1A1 Tank regulator production line and implementing one-piece flow and pull systems that reduced cycle times and improved operational throughput. Consistently delivered cost savings and productivity gains, including a $100K inventory saving from a Six Sigma Greenbelt project.

At Honeywell

Aerospace, led Six Sigma projects that resulted in significant cost avoidance, process optimization, and waste reduction. Work earned multiple accolades, including the Honeywell Operating System (HOS) Marquee Award and ESSM Six Sigma and Lean Expert Awards.

Honeywell Six sigma and lean manufacturing expert

P.Eng