Quality & Continuous Improvement Professional
Last Updated: 21st February 2018 (over 4 years ago)
Summary
team members with the objective tools of the operational excellence toolbox to identify process gaps, prioritize a strategic improvement approach, and lead/teach/coach/mentor teams through the tactical improvement process. Facilitated efforts to positively impact both manufacturing and transactional businesses by $230M+ during career.
Quality Management Systems
QS, ISO & TS Experience
Lean & Value Stream Management
Microsoft, MiniTab & Visio Expert
Six Sigma Black Belt Certified
Strategic Sourcing & Supplier Quality
Six Sigma Master Black Belt Trained
Employee Training
TPM Focused Improvement Pillar Lead
Conflict Resolution
Education
Master of Business Administration (MBA)
Sep 1998
— Aug 1999
Bachelor of Science in Industrial Technology
Sep 1990
— May 1996
Experience
Lean Six Sigma Master Black Belt
Jun 2016
— Dec 2017
Led a slitter/rewinder project that tripled productive throughput on a bottlenecked asset enabling a $4.5M top line growth potential
Led an OEE improvement project on 2 lines that increased incremental production by a projected 280,000 cases annually
Lean Six Sigma Master Black Belt
Sep 2014
— May 2016
Served as leader/mentor for a teams that have realized $200M+ in savings since mid-2014
Managed a portfolio of projects in multiple plants (Gary Works and Mon Valley Works)
Our team was responsible for the creation and successful deployment of US Steel culture change
Division Quality Manager; Freight Car Products
Jan 2012
— Aug 2014
Drove a 25% reduction in cost of quality via statistical problems solving
Initiated ideas and value stream projects that saved FCP $500,000 per annum
Completed QPS (Lean) Level I & II during first 2 years with company
Co-led the council tasked to develop the training and project management for Wabtec’s Six Sigma implementation
Operational Excellence Leader
Jan 2011
— Dec 2011
Implemented the site Total Productive Maintenance (TPM) Program resulting in a 25% reduction in unplanned downtime
Lead 2 large scale defect reduction projects resulting in a projected $1MM annual savings
Co-led the development of the Audi A6 rear window
Director of Quality & Continuous Improvement
Jan 2010
— Dec 2010
Owned and restructured the global warranty policy and system driving a 25% improvement in warranty cost
Realigned the company’s ISO 9001:2008 program for better continuity across sites
Operations Leader (Consultant)
Jun 2007
— Dec 2009
Co-led the team that established supply chain strategies to save $300M of the $5B indirect material spend for Chrysler LLC
Project leader for 3 e-Business process re-designs, delivering an incremental $15M annually to the top line, within the customer’s 6 month project goal (24 Hr. Fitness)
Used best practices and Design for Six Sigma to create the customer service and low cost country sourcing processes for Industriaplex Inc.
Lean Six Sigma Project Manager
Mar 2005
— Jun 2007
Managed the timelines & budgets for projects that impacted key metrics in the business elevating New Castle to DC of the year and Buffalo DC in to the top 10
Focused on inventory accuracy, scrap reduction, rework reduction, and human factors to add financial benefit to the P&L and improve first pass yield in these DEA controlled DC’s
Deployed the philosophies and tools of Lean & Six Sigma to all associates through training
Senior Quality Manager
Nov 2003
— Mar 2005
Initiated projects to improve quality from 92% to 98% in the first year
Deployed the philosophies and tools of Lean Manufacturing & Six Sigma, including DFSS & Stage Gate Process to the engineering and supervisory staff through training
Served as the liaison between the design engineers, the manufacturing plant and suppliers to assure total quality and manufacturability
Continuous Improvement Manager
May 2002
— May 2003
Through projects championed and lead, our teams added $500k to the bottom line ($20M/year sales)
Lead a large scale lean manufacturing project that changed the plant from batch & queue operation to continuous flow operation via value stream management
Certified as ISO internal auditor
Performed six sigma training for staff and hourly employees
Controlled all documentation relating to the justification of capital equipment
Corporate Six Sigma Black Belt
Mar 2001
— May 2002
Through projects I led, my teams reduced operating expense and avoided costs of $14.5M
Manufacturing Engineer & Safety Manager
Dec 1999
— Jan 2001
Performed kaizen events that increased productivity by 25%
Earned Six Sigma Black Belt by completing 5 projects reducing or avoiding costs totaling $435k per year
Served as the safety manager providing OSHA training (501 certified), reporting, and compliance auditing
Worked on a team that received ISO 9001 certification for the surge arrester plant
Product Development Engineer promoted from Process Technician
Jan 1997
— Dec 1999
Facilitated the new & existing product development projects for television
aperture grilles
Design & verification of product & tooling in a photo-chemical etching process
Liaison between internal Japanese customers, the US manufacturing & quality
groups
Technician – 1.5 years
Led process DOE and optimization for 3 projects during the startup of Sony’s
glass plant
Charged with controlling the dimensional integrity of 27” & 32” television glass
panels
