● Case Studies

Results, not adjectives.

Every project below shipped, was used in production, and is backed by a metric — pulled directly from three decades in the field.

$95M UPS Worldport Conveyor Expansion

Siemens · Louisville, KY · 2001–2013

Established the logistics plan and managed material flow from international suppliers, through an offsite warehouse, to a just-in-time delivery schedule for a $95M turnkey conveyor expansion at UPS Worldport. Built a database tying inventory, project schedule, and financials together to guarantee timely billing, and prepared weekly Earned Value Management reports to keep the project on time and on budget.

1st place — 2010 Siemens Mobility Project Excellence Award 2nd place — 2011 IPMA Project Excellence Award Zero costly delays via automated PO tracking

$100M Airport Parcel System

Designed Conveyor Systems · Nashville, TN · 2019–2023

Principal PM team member responsible for the logistics plan and material flow through a 330,000 sq ft offsite warehouse to a limited-access construction site on airport property. Built a Warehouse Management System and a FlexSim model to manage material flow from suppliers to installation teams, plus a Lessons Learned database as an ongoing improvement mechanism — every tool built in MS Office.

330K sq ft warehouse logistics automated Custom WMS built entirely in-house Full schedule-of-values & billing tracking

AWK-Powered CRUD Matrix Generator

Keane, Inc. · Meijer MIDS · 1995–2001

Designed and developed an AWK program that generated a full CRUD matrix report directly from a set of Sybase stored procedures — replacing a manual process across 20,000+ stored procedures that previously required roughly 300 man-hours and was only 90% accurate.

$80,000/yr saved Accuracy 70% → 100% 300 man-hours eliminated per cycle

Taking Over Version Control on Meijer's MIDS

Keane, Inc. · Meijer MIDS · 1995–2001

Joined as an analyst on Meijer's MIDS (Meijer Integrated Distribution System) — a distribution platform built entirely from scratch in PowerBuilder, Sybase SQL, and C++ — and took over version control for the system, engineering his own scripts paired with MS Office, mostly Excel, to manage releases in the absence of dedicated tooling.

PowerBuilder / Sybase SQL / C++ platform Version control built from custom scripts + Excel

Visio-Driven Lean Initiative

Dematic · Grand Rapids, MI · 2013–2017

Authored a Lean initiative using Visio to build logical flow diagrams that automatically generated application configuration files, routing tables, software functional specifications, and test cases/scripts directly from the diagrams — turning process documentation into working project artifacts.

5–8% of project cost saved Configs & specs auto-generated from diagrams

Automated Estimating Suite

Siemens · Installation Estimating · 2001–2006

Developed a software suite for mechanical and electrical installation estimating, plus a series of parametric formulas for generating complete Rough Order of Magnitude (ROM) proposals from historical data and hardware mix.

Estimator productivity doubled Prep time cut 80%+ Accuracy improved 5%

$1.2M Loss-of-Productivity Claim

Siemens · Installation Operations

Identified, reported, and estimated a $1.2M loss-of-productivity claim using specialized claims-analysis techniques — turning a project setback into a substantiated, recoverable claim.

$1.2M claim identified & proven

Zero-Downtime OLAP Migration for Pharmacia

Keane, Inc. · Pharmacia, Kalamazoo, MI · 1999–2001

Reverse-engineered three large Visual Basic financial applications totaling 71,000+ lines of code after Pharmacia's OLAP database vendor dropped support for the version their systems depended on. Converted every API call in the codebase to the interface required by the current OLAP release — completed without interrupting the company's 24/7 worldwide financial operations — and, since no documentation existed, built a parsing tool that generated a full indexed Word manual directly from the source code.

Zero downtime across 24/7 global operations 71,000+ lines migrated & documented Documentation hours cut 50%

Two-Week, $3M Billing System

American Bar Association · 1994–1995

Designed and built a multi-form Excel VBA billing application from scratch in two weeks. The system read a file generated by a mainframe legacy application and produced six different multipage statement layouts — each with a graphic summary page and barcoded information — in time for a $3M billing cycle deadline.

Delivered in 2 weeks $3M billing cycle supported 6 statement formats generated automatically

Gupta-Based Membership, Subscription & Billing Systems

American Bar Association · Chicago, IL · 1994–1995

Alongside the two-week Excel VBA billing project, supported the association's Gupta-based client-server systems that managed memberships, subscriptions, and billing across the organization.

Gupta client-server platform Memberships, subscriptions & billing managed

Automated Tax-Form Generation Engine (AACTS)

Arthur Andersen · Chicago, IL · 1993–1994

Built core pieces of the firm's Corporate Tax Solution (AACTS) — a system written mostly in compiled C — including proprietary tooling that generated the graphical tax forms themselves and mapped every calculated entry to the correct field on each form.

Compiled C calculation engine Automated form generation & field mapping

State Planning Manager — Lotus 123 to Excel Migration

Arthur Andersen · Chicago, IL · 1993–1994

Put his own platform comparison study into practice, migrating the firm's State Planning Manager application from Lotus 123 to Excel — the first hands-on proof that VBA was the right long-term platform, a year before it became the default choice for everything that followed.

Lotus 123 → Excel migration Informed by his own platform comparison study

Standardizing VAX Printer Support Across Thousands of Devices

Dow Chemical Company · Midland, MI · Summer Intern, 1991–1992

Built an automated tool to generate VAX Device Control Libraries for Dow Chemical's VAX team, standardizing how any new printer — across a fleet of thousands of different models — could be added to the system. Completed as an MSU undergraduate intern given direct access to Dow's production systems.

Thousands of printer models standardized Built while still an undergraduate intern

Fair-Share Batch Queue Balancing

Michigan State University · Convex Systems Group · 1988–1992

Wrote a C application that balanced MSU's research computing batch queues, so professors submitting heavy computational jobs could get their fair share of processing power — without being able to monopolize the queue and lock out every other researcher waiting their turn.

Fair-share scheduling across research batch queues

The First Estimating Workbook — Lotus 123

Pyramid Control · Midland, MI · 1980–1988

Years before earning his Computer Science degree, Daniel built his first estimating workbook in Lotus 123 while estimating electrical and controls projects for the chemical, pharmaceutical, and petroleum industries. He developed project schedules, manpower plans, and job-cost tracking for projects ranging from $10,000 to $2 million — the first of dozens of estimating and project-tracking workbooks he'd go on to build over the next four decades.

Projects from $10K to $2M tracked Origin of a 40+ year workbook practice

Want results like these on your project?

Every case study above started as a conversation about a process that was costing more time or money than it should.