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Quality Assurance Manager
ï Conducted Six Sigma DOE studies to qualify 178 SKUs of pencil lacquer in lieu of hazardous chemical compliance legislation for childrenís products. Project mitigated $1.2 million cost risk and is on track to generate $200,000 in usage optimization from key DOE learnings.
ï Maintained a customer/consumer complaints database and generated corrective actions that reduced complaints by 22% in 2007.
ï Implemented APQP/Vendor Certification process for 233 suppliers to track material changes and optimize charge backs that resulted in an 85% reduction of QA hold inventory.
ï Created a supplier ratings database and identified development opportunities for ten suppliers.
ï Generated $60,000 cost avoidance via material standardization and specification evaluations.
ï Delivered $80,000 savings in scrap reduction projects.
ï Standardized visual quality systems to eliminate operator bias.
ï Managed the quality control gate for new product launches including packaging/product design changes, incoming quality processes, pilot runs and first article approvals.
ï Manage eight direct reports.
ï Mentor for engineers pursuing Six Sigma Green Belt training and certification.
ï Plant representative on Global Business Team for Hi-Tech Business Unit.
ï Certified in Newell Rubbermaidís Operational Excellence Training.
Manufacturing Engineer
ï Managed the facilities department including compressed air systems, HVAC, water treatment and construction projects.
ï Completed labor and overhead productivity projects with $830,000 annualized savings involving $600,000 capital investment.
o Automated label stock lines to reduce 20,000 labor hours across 86 SKUs resulting in annualized labor savings of $450,000 with a capital investment of $400,000.
o Collaborated with Supply Chain and marketing groups to drive SKU consolidation and supplier quality agreements resulting in $50,000 annualized savings.
o Conducted a Six-Sigma project to reduce energy usage by 17% via optimization of lighting, compressed air, HVAC and shut-downs resulting in annualized savings of $160,000 and a cost avoidance of $150,000.
o Provided energy consultation to other Sanford facilities in North America to generate $1 million productivity opportunity.
ï Led training and deployment of Overall Equipment Efficiency (ìOEEî) metric, 5-S, Visual Factory and Total Productive Maintenance (TPM).
ï Certified in Newell Rubbermaidís ìProject Management in a Business Environment.î
Continuous Improvement (CI) Engineer
ï Eliminated 12,000 labor hours via a kaizen event and KanBan implementation for packaging efficiency improvements resulting in a $200,000 annualized labor and overhead savings.
ï Conducted SMED projects to reduce changeovers by over 50%. Related improvements resulted in annualized labor and material savings of $58,000.
ï Project Engineer for pen-point fabrication operations relocation to Low Cost Country.
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ï Conducted a process capability study to evaluate ergonomics of a fastener assembly operation.
ï Performed computer simulations to evaluate the stresses on fasteners and support units that resulted in elimination of 2% non-value-added fasteners in assembly components.
ï Conducted time studies for equipment specifications and performance benchmarking for roll formers, panel benders, turnkey polyurethane foam systems and NC punch machines.
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