FRANK FERNANDEZ

*** ****** *** – Alpharetta GA **022

404-***-**** – actdvq@r.postjobfree.com

CONTINUOUS IMPROVEMENT/MANUFACTURING OPERATIONS

Providing Solutions for High Profile Employers and Client Companies, Including Siemens Industry, Carrier Corporation, Husky Injection Molding Systems, General Motors, Cintas Corporation, Bombardier and United Technologies

Manufacturing Operations Executive and Lean/Six Sigma trained Engineer with over 20 years of experience and consistent success in achieving revenue, cost reduction and continuous improvement goals. Able to guide and lead highly skilled multi-functional teams in the design, development and implementation of leading edge solutions and processes using Lean Manufacturing principles. Effective analyst, problem solver, and communicator. Vast international experience

Core Competencies:

Certified Lean/Six Sigma Champion

Lean Implementation/Transformation

Operations & Process Reengineering

Kaizen Event Team Leader/Sponsor

Quality Assurance Control/Standards

Lean – 5S, Kanban, Value Stream Mapping, TPM

Start Up & Turnaround Operations

Problem Solving / Change Management

International Technology Transfer

Team Building, Mentoring & Leadership

KEY PROFESSIONAL EXPERIENCE

MILLENNIUM MAT COMPANY, Suwanee, GA

Continuous Improvement Manager (4/2015 – Present)

Responsible for increasing the overall efficiencies and productivity across the US and UK facilities to provide world class quality products, processes and systems while driving timely corrective action and training. Implement new processesor revised process requirements. Determines and establishes systematic improvements to promote and sustain long-term continuous improvement programs. Leads Continuous Improvement team providing direction, coaching, goal setting and training.

SELECTED ACCOMPLISHMENTS:

Lean Transformation – Designed a lean implementation program, Started with the rollout of a 5S program throughout both the US and UK plants. Instituted a rigorous system of weekly audits and corrective action implementation to ensure sustainment. Implemented Service Level Agreements between internal customers and suppliers to improve communication and enhance teamwork

Training – Designed and implemented a formal training plan for all shop floor employees. Plan consists of Job Descriptions for all departments, instituting Minimum Required Training for all positions,, the creation of a Skills Matrix for all positions, and the implementation of Employee Transcripts for both exempt and non-exempt personnel

Corrective/Preventative Actions – Implemented an 8Di process to formalize problem resolution by ensuring a Root Cause analysis discipline, ensuring actions and processes changes are designed to eliminate the actual causes and not just the visible symptoms

CANFER GROUP, Monterrey, Mexico

Director of Operations, Newland de Mexico (6/2008-4/2015)

Oversee core business and operational development functions (Production, Quality Control, Material Management, Human Resources, Planning, Customer Service) within manufacturing operations. Supervise staff of 145 direct and indirect employees and direct systems implementation to support major contracts with Husky Injection Molding Systems and Carrier Corporation. Perform Project Management function and handle customer relationships.

SELECTED ACCOMPLISHMENTS:

Continuous Improvement –Led kaizen event that improved On Time Delivery from 12% at startup to 95% by implementing project planning system based on teamwork, internal quality and customer satisfaction goals. Developed capacity loading requirements to further enhance on-time delivery initiatives and forecasting needs. One piece flow process driven by Takt Time was extended to the Cable Assembly cells, increasing throughput by 40%

Process Design – Designed all manufacturing processes following Lean Manufacturing principles, including a 5S Program, One Piece Flow production, Kanban for material management and Visual Factory elements throughout the plant, In-process inspection standard rolled out throughout production reduced quality technician headcount while improving quality as measured by Non Conformances per Shipment reduced by 65%

Process Enhancement – Established continuous improvement teams throughout organization to reduce costs and increase margins, using tools such as Kaizen events,VSM, RRCA, and FMEA, Implemented SAP Business One including MRP module to enhance purchasing and inventory management processes.

Organizational Development – Led effort to design, implement and manage a manufacturing organization from the ground up, including all manufacturing and most business processes, hiring of all staff and floor level employees

Sales Growth – Played central role in increasing sales from $0 to $8.1 Million in a 3 year timeframe through effective project management and operation management strategies. Negotiated a transparent business model with customer which simplified quoting process and allowed for faster ramp up to full production. In year 3 of project renegotiated with customer a new model for costing of class c items increasing revenue for these materials by 100%

Project Management – Function as main contact with customer, both on the commercial and technical aspects. Generated project plans for project startup as well as all new product introductions. Worked with customer’s Design Engineering department to ensure smooth introduction and ramp up.

SIEMENS INDUSTRY, Alpharetta, Ga.(1998-2008)

Manufacturing Engineering Manager (11/2005-5/2008)

DUTIES AND RESPONSIBILITIES INCLUDE:

Manage team of 12 manufacturing engineers including 1 Six Sigma Black Belt and 2 Green Belts

Assign and manage Six Sigma Projects within the plant

Assist team with various tasks, including new process implementation, new project development, and continuous improvement activities

Provide training and assistance to Manufacturing Engineering team in Lean Manufacturing techniques

Implement and administer plant 5S program, including employee training of 5S activities and training of 5S champions

Develop and maintain budget of Manufacturing Engineering department

Wire Center – management of 50 employee production department

Test Engineering – responsibility for test engineering plant wide

Facilities – Supervision of Facilities Manager and all aspects of the facilities management function, including responsibility for Employee Health and Safety

Training – Responsibility for employee technical training; Development of Workshop Certification Program; Supervised Facility Training Instructor

SELECTED ACCOMPLISHMENTS:

Earned top score in Aspects of Leadership, for all Division Managers for three years in a row (2005-2007)

Coordinated shingijutsu event with key supplier (Carrier Corporation, 2007)

General Motors Project - Operations Project Manager for GM Panel project, a 30M M Euro global project.

Responsibilities included the design of the production process, material delivery systems, coordination with key suppliers, and liaison with customer to ensure all requirements were met. Project successfully launched in July 2007. System in place was able to handle increased customer requirements, which increased from 3500 hrs in July 2007 to over 10,000 hours in September 2007.

Conquest Outsource Project – Direct and implement all activities related to the outsource of two control panel production lines. Scope of responsibilities included:

Selection and supplier development of outsource partner in Mexico. Negotiation of supplier contract

Development of project plan for all activities related to physical move of production lines

Management of the entire process, including the establishment of the export process for all materials under the Mexican maquiladora program, training of all employees in Mexico, and implementation of production control process. Pilot line program implementation in November 2006. Project delivered savings of $1.4 MM/yr

Full program implementation in January 2007. Move was executed without affecting customer deliveries.

Sr. Manufacturing Engineer (10/2002-11/2005)

Manufacturing Engineer (10/98-10/2002)

DUTIES AND RESPONSIBILITIES INCLUDE:

• Sole responsibility for manufacturing process design, technical support, and continuous process improvement for major projects:

United Technologies-Carrier - $17MM/yr

United Technologies-UTC Fuel Cells PC25 and Pure Cycle 200

Siemens Drives Solutions – project value - $10MM/yr

Uniloy Milacron - $3.5MM/yr

Tokyo Electron Limited - $2.0MM/yr

Trumpf Laser Cutting Systems – $2.8MM/yr

• Estimating manufacturing labor requirements for new and existing projects (Reading/interpreting assembly drawings/electrical schematics)

SELECTED ACCOMPLISHMENTS:

• Design and implementation of lean one-piece flow production lines for Carrier Aquasnap, Conquest A, Conquest Z, Starfire and Thunderbolt Projects and Dematic Stacker project

•Aquasnap and Conquest lines achieved 100% on-time shipment for first two years with efficiency levels near 100%

•Nominated for PCD Employee of The Year Award/Operations, 2003

•Introduced use of kanban replenishment strategy for point-of-use parts storage . Implemented kanban in Aquasnap, Conquest A, Conquest Z, Starfire,Thunderbolt, and Dematic Stacker Projects

•Assisted in SAP implementation for PCD division; took lead role in changeover of kanban system to SAP

•Developed a PC-based tool for generating labor estimates, reducing quoting time by 50%

• Redesign and implementation of new facility layout for Drive Products Department, resulting in savings of $50k/yr and on-time delivery improvement from 78 to 100%

• Conceived/implemented automated wire processing center saving $158k/yr

•Design and implementation of returnable shipping containers for Aquasnap, Conquest A, Conquest Z, Starfire and Thunderbolt projects, saving $80,000 annually over expendable packaging concepts.

COLOPLAST CORPORATION, Marietta, Ga.(1991-1998)

Supervisor, Component Manufacturing and Packaging (12/1994-10/1998)

DUTIES AND RESPONSIBILITIES INCLUDE:

•Supervise, schedule, and train employees

• Preparing and administering a $950,000 annual budget

• Lead, assist, or participate in New Product Development projects

SELECTED ACCOMPLISHMENTS:

• Design, install and implement a one-piece flow lean production line; throughput increased from 30K/year to 170K/year.

• Design and implement a packaging process and layout that increased labor efficiency by 75% and throughput by 400 %

• Leader of Corporate Teams Implementation Team, responsible for the development of a team structure model and tools to enhance company team environment. Trained employees in Team Basics; Trained management team of Costa Rica plant in Team Basics and Theory. Coached several teams.

Manufacturing Engineer (9/1991-12/1994)

DUTIES AND RESPONSIBILITIES INCLUDE:

• Handling and solving manufacturing problems

• Give staff assistance to other Operations departments in material handling, ergonomic and other system integration projects

SELECTED ACCOMPLISHMENTS:

• Designed, implemented, and managed a kanban system for internal sub-assemblies and components; Reduced out of stock situations by 75%

• Design and implementation of in-line seal modification device reduced internal reject rate by 30% and reduced field returns by 90 %, saving the company $160,000 per year; Earned corporate Process Improvement award

• Design and implement a Shop-Floor Production Control system; wrote technical manual and operator manual; system reduced WIP by 90%

EDUCATION AND SKILLS

Georgia Institute of Technology, Atlanta, Ga.

Bachelor's degree in Industrial and Systems Engineering, December 1989

Skills and Training

MS-Office Applications, MS-Project, AutoCAD,Visio

Extensive SAP/R3 and AS/400 experience

Fully bilingual (English/Spanish)

Technical Writing (ISO, S.O.P.’s, Training manuals)

Green Belt Certification Pending (March 2016)

Lean Manufacturing

ISO Implementation

Total Quality Management Certified

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