Robert B. Lettan

*** ***** ***** *****

Townville, South Carolina 29689

abnrcl@r.postjobfree.com

864-***-**** (home)

864-***-**** (cell)

Objective:

Obtain a challenging “Operational Quality” position that offers opportunity to build professional

relationships, optimize process efficiency / cost of quality, foster a cultural of continual improvement, and

significantly contribute to the success of the company.

Summary of Skills:

Certified (1998) Six-Sigma / Lean Senior Black Belt - experienced practitioner (Master level),

countless success, driven on continuous improvement through waste and variation reduction.

Strong training and project management skills with a well organized, planned, and systematic

approach in tackling tasks, communicating / transferring skills, and completing assignments.

Excellent analytical, problem solving, communication, and interpersonal skills with the ability to

get along well with people from various cultures, backgrounds and management levels.

Excellent facilitation and team leadership skills with shop floor roll-up-the-sleeves involvement.

Practitioner of process improvement tools including Lean, Six Sigma, TPM, QSB, TOC,

Capacity, OEE, MBF, RCA, and COQ.

Extensive international manufacturing experience and exposure with Canada, Mexico, Brazil,

United Kingdom, Germany, and Turkey.

Team player with consistent positive “can do” attitude.

Experienced in multiple disciplines: Powder Metal, Machining, forging, plastic injection

molding, aluminum die-casting, sub-assembly, final assembly as well as transactional processes.

Highly skilled with PC: Outlook, MSWord, MSExcel, Power Point, and Minitab statistical

software.

Experienced in highly responsible positions within supply chain management, quality, and

manufacturing.

Performance characterized by integrity, dedication, and commitment to process improvement,

customer satisfaction, and business results.

Experience:

ESAB Welding and Cutting Products Florence, SC

IT Manufacturing Business Analyst (07/08 - 02/09)

Change Agent / IT Interface with the ERPLx implementation among Production, Purchasing, and

Quality across five North America Manufacturing facilities

Established / modeled mapping of processes (baseline) to identify current interrelation of data

systems, information flow, and work processes for development of application requirements.

Conducted process studies, applied lean / six sigma, and implemented process improvements.

Facilitated workshops in support of sharing best practices across ESAB’s five purchasing

departments.

RFL: Downsized - Due to lack of sales as well as ERPLx Project placed on hold.

Robert B. Lettan Page # 2

Borg-Warner Automotive Seneca, SC

Value Improvement Manager / Engineer (04/02 - 06/08)

Created and managed BorgWarner’s “Supplier Value Improvement Program” to partner with and

key suppliers and improve their processes (QCD’s) via training / application of Lean / Six Sigma.

Initiated and set Supplier's foundation for cultural change of “continuous process improvement.”

Conducted Supplier Process Assessments to identify cost and productivity opportunities.

Conducted high-level meetings / presentations with Plant Managers and their management staff.

Applied and conducted: Kan ban, Kaizen, 5S, Visual aids, Value Stream Mapping, Process

Mapping, Capacity & Capability studies, Line-balancing, Setup reduction, One-piece flow, WIP

reduction, TOC, Poka-yokes, MSAs, DOEs, PFMEAs, DMAIC, TPM, TPS, and QSB to

improve / optimize processes.

Lead / manage projects, train / mentor engineers, and achieve in excess $1 million + per year

savings via Defect elimination, and Waste reduction, and Variation reduction.

Some Project Accomplishments (annual savings):

Applied Lean tools (set-up reduction, 5S) Bengal Industries Plastic Injection ($857K).

Applied Lean tools (one-piece flow) with Brockway Powder Metal Process ($247K).

Applied Six Sigma (DMAIC) and Lean (Value Analysis) to the Livonia Powder Metal to

eliminate outside sort and reduce process waste ($1,076K).

Applied Six Sigma tools to eliminate hard spots in aluminum castings that cause machining tool

damage, lost productivity, and defective parts ($400K).

Resolved critical supplier issues as Champion Lean / Six-Sigma practitioner, trainer, and leader.

Facilitated, coached, and Implemented "Quality System Basics" across top 13 critical suppliers to

instill process integrity.

RFL: Promotional / Growth Opportunity with ESAB Welding & Cutting Products

Maytag Corporation Jefferson City, MO

Quality & Lean Sigma Manager (04/01 - 02/02)

Responsible for defining and establishing “Manufacturing Quality Systems” for new appliance

during product development phase.

Managed / supervised 5 direct reports (QE, Inspector, SQE, Administrator, and Lab Technician).

Lead, facilitated, and supported the development of quality systems as well as control plans and

Kaizen events in support of operation's achievement of a "lean one-piece flow" pull system.

Mentored and assisted Lean Sigma green belts with Thought Process Mapping, Process Mapping,

FMEAs, MSAs, and Capability Studies (Cpk, Minitab, and JMP).

Responsible for Controls Plans, Flow Diagrams, PPAPs, and PFMEAs.

Provided final assembly verification testing to identify additional assembly process improvement

opportunities and ensure quality units for design engineering field test.

RFL: Downsized - after Amana buyout

Robert B. Lettan Page # 3

Xerox Corporation Rochester, NY

TQM Quality Specialist (07/91 – 01/01)

Certified Six-Sigma / Lean Senior Black Belt 1998 (Six Sigma Systems) Completed Master

Black Belt classes - 2000

Supported development, training, and implementation of Quality Programs (Six Sigma, Lean,

Kaizen activities, Cost of Quality, Management by Fact, and Root Cause Analysis) in Brazil,

Mexico, Canada and United States Manufacturing operations.

Coordinated the annual Canadian & Latin America Manufacturing Team Excellence Conference.

Investigated, analyzed, and resolved manufacturing, distribution, service and administrative

process issues resulting in significant productivity gains and dollar savings. Mentored

manufacturing engineers with Six-Sigma to assist them in achieving black belt certification.

Lead and facilitated cross-functional international teams in the development and implementation

of benchmark manufacturing customer satisfaction systems in support of business objectives.

Some project activity accomplishments:

Reduced variation on Canada document handler production line ($153K savings).

Introduced Lean concepts on Brazil finisher product line (WIP savings of $850K).

Identified / corrected numerous manufacturing measurement system deficiencies.

Reduced occurrence of flash and short shots with high volume plastic injection ($280K savings).

Identified / resolved transportation damage from Mexico manufacturing ($850K savings per

year).

RFL: Downsized - Due to lack of sales

Education:

University of Rochester Rochester, New York

Masters in Business Administration (William E. Simon Graduate School of Business Administration)

3.2 GPA

Stetson University De Land, Florida

Bachelors in Business Administration

3.0 GPA

Monroe Community College Rochester, New York

Associates in Engineering Science

2.8 GPA

Military

United States Air Force Weapons Control System Specialist (E-4)

Air Force Commendation Medal

Honorable Discharge

References

Professional References available upon request.

Contact this candidate