Six Sigma Quality

James Donnachie

Contact Information

Address: Jaimee’s Hotel, Seaside Ibarra, Maasin City, Southern

Leyte, Philippines. 6600

Tel: +639*********

Experience Overview:

I am a hand’s on, results driven Senior Executive in Quality, Program

Management and Continuous Improvement within the automotive

manufacturing sector. This led to my previous position held for 12 years as

a Vice President for Johnson Controls Incorporated (JCI).

In the last 20 years while in Johnson Controls I worked in Asia for a total

period of 15 years supporting JCI growth in Asia.

Additionally I have hands-on experience in strategic planning, international

JV formation and experience in starting over 42 (Greenfield or Brownfield)

manufacturing plants for automotive systems and components

manufacture.

In-depth knowledge of Six Sigma (certified MBB), 8D Problem Solving,

FMEA, SPC, APQP, QS9000, TS16949, and BS5750 (Consultant).

Current Position: I left JCI in Oct 2013 to build and manage my own Hotel

in Maasin City, Southern Leyte, Philippines.

I have contracted back to JCI for special assignment projects on three

occasions.

March 2008 – Oct 2011. Johnson Controls Automotive (JCI) – India &

SE Asia

Position: VP Quality & Program Management

• Based in Singapore I was responsible for the regional quality

performance and program launches of 7 plants in India, 4 in Malaysia, 2

in Indonesia and 2 in Thailand.

• Supported the launch of five new manufacturing plants from 2008 to 2011.

• Launched 28 new product programs in the region for various automotive

customers including Toyota, Ford, GM, Nissan, Mitsubishi and TATA

Motor Company.

• Reporting to me directly in Singapore was one Regional Quality Systems

Dir and one Regional Program Systems Coordinator and by location five

Country Directors of Quality and five Directors of Program Management.

March 2006 – Feb 2008. Johnson Controls Automotive (JCI) – Europe

Position: Vice President Program Management.

• In Dec 2005 I was appointed European Vice President of Program

Management. Reporting to the VP of Europe I was responsible for overall

project planning, implementation and launches of over 120 automotive

programs in two years. This position was based in Burschied, Germany.

• The European structure in JCI at that time had 75 manufacturing plants in

Europe. In total 12 Directors of Program Management were reporting

directly to me and there were 220 Program Managers in total within the

European business. In addition a central staff of 4 people (2 Senior PM’s,

1 IT Support Engineer and 1 Project Coordinator) were directly reporting

to me.

• New program planning had 3.5 Billion US$ of replacement business for

new projects launched in that two year period.

• Best Business Practices (BBP) system for Program Management

introduced in six months. All major projects launched since my

appointment were all within baseline business plans.

• Launch Performance in FY06 improved by 22% from 2005 results

(measured as – 0 RPPM, 100% manufacturing efficiency, 100% financials

targets met measured 30days after launch, within the baseline Business

Plan)

1999 – 2006. Johnson Controls Automotive (JCI) –Asia Pacific & Japan

Position: VP Quality/Program Management/Six Sigma/Lean.

• In 1999 JCI launched a Six Sigma/Lean initiative and I was given

responsibility for Continuous Improvement (Six Sigma + Lean) for the Asia

region. Trained by the Six Sigma Academy from the US I certified as a Six

Sigma Black Belt in May2000, further trained by JCI internal MBB’s and in

June 2004 was certified as a MBB.

• Developed a regional Six Sigma Master Black Belt team and grew the

region to achieve 30 MBB’s, 210 BB’s and 389 Green Belts.

• Implemented a CI Group (Six Sigma + Lean) developing regional Process

Engineers to Lean Implementers. This resulted in 80 Lean Implementers

being available in 1.5 years

• Achieved Continuous Improvement (Six Sigma + Lean) savings in 6 years

of 17 million US $.

1995 – 1999. Johnson Controls Automotive (JCI) – Asia Pacific & Japan

Position: Director Quality/Program Management

• Due to the development of JCI business in Asia I was appointed the first

Director of Quality for Asia Pacific and Japan, based in Singapore initially

responsible for two manufacturing locations, one in Australia and one in

Japan. In three years through acquisition, JV formation and generic

growth JCI in 2006 have 30 manufacturing plants in Asia Pacific and

Japan.

• Supplying Ford, GM, Toyota, Nissan, VW, Mitsubishi and other local

Asian OEM’s.

• Additionally in 1997 I was given additional responsibilities for Program

Management for the region.

• Recruited trained, developed and coached Quality Directors and Program

Management Directors in the Region.

• Achieved TS16949 in all locations within 1 year of the plant launching.

• Launched all projects in the Region 98% within company measurables

(120 plus projects).

• Trained all PM’s in Microsoft Project/JCI Program Management Systems.

1993 – 1995. Johnson Controls Automotive (JCI) – Ford Business Unit

Position: Director Quality.

• In 1995 I was appointed the Dir Quality for the new Ford Business Unit

being formed in Europe, supplying Ford Motor Company Europe with

6,000 vehicle seating systems per day from 5 plants for Ford Escort and

Ford Fiesta vehicles. Reporting to the VP Ford Business Europe I was

responsible for recruiting and developing the quality organization for 5

new plants in Europe.

• Launched 5 manufacturing plants within one year of construction start

specifying quality organizations, equipment, systems and training for the

complete quality staff.

• Achieved Ford Q1certification for all 5 plants within 18 months of startup.

• Achieved QS9000 in all plants within 16 months of startup.

1992 – 1993. Johnson Controls Automotive (JCI)

Position: Group Quality Manager UK.

• In 1992 my responsibilities in the UK were increased to include a 2nd

metal plant in Telford and a seating polyurethane foam plant in Silloth.

Reporting to the UK General Manager I was responsible for 3 Quality

Managers and 17 Quality Engineers

• Achieved BS5750 Part 1 accreditation from BSI for all plants and Ford

Q1certification for Essex and Telford.

• Achieved QS9000 certification by BSI in all plants during 1993.

• Reduced group quality rejections from 1,600 RPPM to 300RPPM in six

months after appointment.

1991 – 1992. Johnson Controls Automotive (JCI) Metal Plant

Position: Quality Manager

• Based in Essex in the UK and responsible for the Quality

Assurance/Control of a metal plant producing metal seating components

for Ford Motor Company. Reporting to the Plant Manager I was

responsible for 3 Quality Engineers and 6 Inspectors in this metal plant

which employed 120 people.

• Achieved BS5750 Part 1 accreditation from BSI and Ford Q1certification.

• Reduced customer rejections by 40% to 30RPPM.

• Reduced warranty costs by 75% in 1.5 years.

PREVIOUS EMPLOYMENT SUMMARY

1988/1991 - McCrae Quality Consultants - Quality Consultant

Training Quality Systems (BS5750) and implementing Quality Management

Systems in various companies.

1986/1988 - British Aerospace - Space and Communication Division-

Senior Metrologist /Quality Control Manager

The measurement of satellite structures used on the Ariane Satellite.

Calibration of all measurement and testing within the company.

1983/1986 - Northrop Aircraft Corp - PMEL Technician - Saudi Arabia

Responsible for the mechanical calibration department for the Saudi Air

Force Precision Measurement Laboratory based in Dhahran, Saudi Arabia.

Equipment and instrument calibration for the F15 fighter aircraft.

1978/1983 - AMP UK Ltd - Electronic Components – Mechanical

Calibration Engineer Mechanical calibration of general measuring and

test equipment.

1970/1978 - John G Kincaid Ltd - Marine Engineering - Mechanical

Engineer (apprenticeship served).

• Mechanical Engineer responsible for the assy and testing of marine

engines used for large container vessels. Served a four year EITB

Mechanical Engineering Apprenticeship.

EDUCATION

• Mechanical Engineering Degree from Glasgow University in Scotland in

1977.

• Four year Mechanical Engineering apprenticeship from JG Kincaid

(Marine Engineers).

• I am a company certified Six Sigma BB and MBB. I have been trained by

Harold Kersner in Program Management

• Attended courses in Problem Solving, FMEA.SPC, AQP, QS9000,

TS16949, BS5750, and ISO9000.

• UK Institute of Quality Assurance Lead Assessor Certified.

GENERAL

Marital Status: Divorced with no dependent children.

DOB: January 15th 1955.

Hobbies: Music (composing, playing, recording and post production).

Contact this candidate