Stephen Sutcliffe

Phone: 910-***-****

Email stevesutcliffe845@msn com

Summary: Operations & Quality Excellence Work Experience

Strengths:

Development of lean cellular manufacturing with improved plant layouts and processes

Experienced in automotive supplier manufacturing development for new product Introduction NPPD&I

Development of lean cellular manufacturing with improved plant layouts and processes

Successful value stream re-mapping of critical processes and implementation of lean methodologies

Administration & facilitation of Quality Management Systems

Successful project leadership implementation of lean concepts and change management

Successful introduction and roll out of Automotive APQP

Training facilitation, coaching and leadership skills

Project Management skills

Planning and Organizational skills

A team player with excellent interpersonal, motivation & management skills, driving the culture change

Project /time management driven, enthusiastic, proactive, and keen to take on new roles and challenges

Prioritizes Safety as No 1 priority in all decision making

Skilled in a wide use of problem solving tools

Documenting Procedures and Document Management Systems

Training & Certification:

Supervisory Management (Front Line Supervisor)

Problem Solving

Lean Manufacturing Techniques

Lead Auditor ISO 9001

QS9000/ISO-TS16949, ISO9000-2000 Quality Systems

Lotus Notes – QSI database quality document management systems

Environmental & Safety (ISO 14001)

Lloyds of London (LRQA) Institute of Quality Assurance

Total Productive Management - (TPM)

Cummins Total Quality Management Systems (TQS)

Automotive Quality Systems AIAG – Advanced Product Quality Planning (APQP/NPPD&I)

6 Sigma Methodologies, Toyota Production Systems (TPS)

Engineering Apprentice (Timken Bearing Company)

Project Management Skills

Time Management Skills

Facilitation & Presentation Skills

Instructional Techniques (Train The Trainer)

Assertiveness for Personal Effectiveness

Geometric Tolerancing

Gauge R&R

London Chamber of Commerce - German Language

Education:

Manufacturing Engineering Machining (City & Guilds of London Institute/ASCET)

Electrical Mechanical Engineering (City & Guilds of London Institute/ASCET)

Certified Engineer (Engineering Board of Trade U K)

BSME Mechanical Engineering – GPA B (3 4)

Northampton College of Engineering Technology, Northampton, England UK

Key tools and concepts applied to preprocess improvement:

New Product Introduction NPPD&I,

Production Part Approval Process (PPAP)

6 Sigma statistical analysis

DMAIC Six Sigma improvement projects

Kaizen

5 S

Value Stream Mapping (VSM)

Rapid changeover of tooling and process set-ups (SMED)

Total Productive/Autonomous Maintenance - (TPM)

Training Programs (Train The Trainer)

Development for Accountability & Responsibility (RACI)

Root Cause Analysis (RCA)

Design for Manufacturing (PFMEA)

Document management systems– Process & SOP Procedures

Critical Risk Assessment

Computer Skills:

Certified Microsoft Excel, Microsoft Word, Microsoft Access, PowerPoint

Certified Lotus Notes Administrator

QSI Quality Systems Information data base administrator

Employment History:

Freelance Technical Adviser Senior Consultant - Operations Excellence Nov 2015-to date

Senior Management Consultant Operations Excellence

MTG/Worley Parsons Consulting - Houston Texas Aug -2013 to Nov 2015

Celerant /Hitachi Consulting – Lexington, MA Jan 2011- Aug 2013

Freelance Technical Adviser Senior Consultant - Operations Excellence Aug 2009-Jan 2011

Operations Manager - Dec 2006 – Aug 2009

Terex/North American Cranes – Wilmington NC

Senior Consultant - Operations Excellence –Feb 2004 – Dec 2006

Management Resources Group Inc., Connecticut/Allied Services Group

Reliability Engineer - Pharma Care Inc., Pensacola FL Nov 2002- Feb 2004

Operations & Quality Systems Manager

Cummins Engine Company UK, Nov 1991– Nov 2002 (Relocate to US)

OPERATIONS MANAGEMENT – 3 Years

Operations Manager Terex Cranes, Wilmington NC

Objectives:

Provide the strategy and project planning for the upgrade of an existing and aging 50 year old facility on a 260 acre site, formally Babcock Wilcox Company now owned by Terex North American Crane Company.

Provide leadership, cultural change and support for improved safety, product quality, and increased manufacturing capability.

Provide technical support for the restoration of plant buildings, structures, facilities, utilities and production equipment upgrades and new layouts

Introduce lean methodologies tools and techniques to achieve increased production targets, product quality and create a cultural change that embraces continuous improvement.

Deliverables:

Organize and train organization cross functional problem solving teams; utilize improvement programs of Kaizen, 5S, 6 Sigma and DMAIC, utilize Root Cause Analysis (RCA) and (FMEA) techniques

Develop and implement Standard Operations systems, shutdown, start-up and process control procedures

Formalize work groups; provide lean manufacturing improvement techniques and training, apply production process improvement philosophies of TPM, and techniques of lean manufacturing, Kaizen, Kanban, SPC, JIT, VSM, SMED to the work place

Create Standard Work operations, Process Control documents

Roll out performance metrics

Maintain daily office administrative responsibilities, supervise department staff, machine operators, welders, preparation & assembly, maintenance technicians and on site contractors

Ensure the smooth running of both production and maintenance departments, prepare and account for department annual budgets (AOP), provide formalized request and account for contractor selection capital plant upgrades and projects funding ($4 0 m)

Provide project planning & leadership; facilitate maintenance and manufacturing engineering improvement programs, to include new and refurbished equipment, new plant layouts for cell manufacturing, improved buildings, facilities utilities, production and tooling equipment

Manage operator skills training programs and Individual Development Plans (IDP’s)

Conduct daily departmental safety & production team meetings and attend daily group leadership meetings

Summary:

All plant restoration projects were completed on time Aug 2009

Production and quality improvement targets exceeded plan, achieving RFT of 20% to 100%, with an increase OEE from 25% to 98% Reliability Centered Maintenance (RCM) improvement initiatives increased available equipment uptime from 70% to 99 5 %

Lean activities integrated into daily operating plan and audited for continuous improvement

PRODUCTION GROUP LEADER: Cummins Engine Co, England UK - 2 Years

Front line production supervisor for: General Machine Shop, Engine Block Machining, Assembly and Test, Shipping and Distribution of Diesel Engines, LPG Engines and Power Generators

Facilitate TPM lean manufacturing improvement, and Cummins TPS Quality Systems

Develop and Manage operator skills training programs

SENIOR SUPPLIER QUALITY IMPROVEMENT ENGINEER: Cummins Engine Company -6 Years

Successfully train and develop key suppliers in the applications and elements of the automotive AIAG – ISO/TS16949, QS9000 production quality system, resulting in 100% successful production readiness, ensuring product and processes meet and exceed the requirements of the automotive APQP program

Lead Quality Engineer for Cummins Engine Co platform and problem solving teams, successfully facilitating and resolving Design, Production, Installation, and Service issues

Coordinate quality control activities for engineering design and manufacturing, liaise between manufacturer and design engineering departments, facilitate design & drawing reviews, validate product reliability through LCA, and FE testing, demonstrate product capability through D O E, and process capability through 6 sigma statistical analysis

Coordinate receiving inspection planning, and supplier performance programs, maintain corrective action follow-up, supplier development and maintain supplier SQA improvement programs

Responsible to the European Purchasing Group to conduct supplier evaluation, source approval and procurement of commodities for both existing and new product introduction – Europe & USA

Maintain and improve the supply base quality within the Cummins organization

QUALITY MANAGEMENT - 2 Years

Quality Systems Manager: Cummins Engine Company - 2Years

Responsible directly to the Cummins Engine plant manager, maintain ISO 9001 / ISO 9000/2000 quality systems programs and annual accreditation

Lead Auditor for automotive TS16949 & ISO 9001/ISO 9000/2000 quality systems

Train all internal departmental quality representatives for documented management systems, procedures, work instruction edits, and internal audits

Successfully convert all of companies’ hard quality documents and forms to electronic format

Successfully develop, train users and roll out the Lotus Notes QSI computerized quality document management system

SENIOR MANAGEMENT CONSULTANT FOR OPERATIONS EXCELLENCE - 6 Years

Objectives:

Develop the business and benefits case through on site structured workshop analysis of the clients operations and quality management systems

Develop improvement project work streams for Operations Excellence

Develop Project Definition (Analysis)

Project Development – design the improved process and systems

Install the systems (Implementation)

Provide the coaching, drive the culture change

Develop and install KPI’s

Monitor measure and sustain promote continuous improvement

Deliverables:

Measurable sustainable results

All staff completely on board and committed to achieving improvement goals and objectives

Achieving substantial annualized savings for clients in benefits over the last 12 months

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