Dan Leveille CPIM, MBA

***** ****** **** **** ** 678-***-**** Cell

Prior Lake, MN 55372 acwe7u@r.postjobfree.com

Organization leader with more than 20 years experience as a business process improvement change agent focusing on developing and managing leading edge international supply chains, new product introductions, design and test for manufacturability and accelerated growth. Demonstrated experience in Lean Manufacturing and Kaizen Improvements.

Proven success and expertise demonstrated in:

Supply Chain Management- Strategic Sourcing

Spend Analysis Optimization - Negotiations

Excess and Obsolete Minimization / PLM Management

NPI and EOL Management

Product Realization – Time to Revenue

Customer/Employee/Vendor Relations

Strategic Goal Setting, Planning & Execution

Tactical Program Management – Attains Goals

Material/Productivity/Cost Reduction Projects

Plant Management & Optimization, Domestic & International (Select, Set Up/Green Field and Manage)

Demonstrated success in ISO and Lean Manufacturing

Director of Manufacturing and Quality May, 2011 – Present

Digi International Minnetonka, Minnesota

http://www.digi.com;

Director of Manufacturing and Quality at Digi, a leader in M2M solutions. Digi is a $200M company in the Wi-Fi, cellular, satellite communication component and module market space shipping 3.3M units per year consisting of 2,100 SKUs. Hands on responsibility for installation, qualification, performance of internal production, supply chain test and quality governance. Supply base in Thailand, Indonesia, Mexico and China. Manage internal NPI capability (SMT and Test), receiving, quality, process and test engineering (component, board and system) and reverse logistics management (RMAs). This is a high tech company with an outsource business model where prototypes and pilot runs are produced internally. Responsible for NPI at off shore facilities. Products are electronics, sheet metal and plastics. My expertise includes printed circuit boards, circuit card assembly, cable and wire harness, mechanical assembly, machining, sheet-metal, plastics, test equipment selection and maintenance, environmental testing and stress screening (HALT and HASS) and implementing RoHS II/WEEE initiatives. Implemented ISO 14001. Implementing/ pursuing ISO 13485 compliance for Class II devices. Implemented DMFEA, PMFEA and Risk Assessment processes. Support/implemented ISO 27001 Information Security Management Systems.

This is a low volume, quick turn operation focused on prototype and low volume production. Manage NPI verification and qualification process and transfer qualification verification to offshore manufacturing facility. 2013 the shop produced 3600 prototypes. Improved first pass yield from 95% to 98.5% now 99%. Reduced cycle time by 30% thru one piece flow. Responsible for DFM/DFT reviews and strategies. Lean, 5S, Kaizen, KanBan, value stream mapping and DMAIC/Quality. Reduce RMA turn time from 18 days to 4 days.

Vice President of Manufacturing/Supply Chain Management Feb. 2002 – April, 2011

Enablence Systems Alpharetta, Georgia

http://www.enablence.com/

Vice-President of Manufacturing/Supply Chain for Enablence Systems a leader in fiber to the home solutions for video, voice and high bandwidth services. Hands on responsibility for Supply Chain Management, forecasting, NPI, production, materials, QAD MRP production control, shipping and receiving, quality, manufacturing and test engineering (component, board and system), web-based ECO/Parts Data Management System (Arena) and reverse logistics management (RMAs). This is a high tech company with an outsource business model where prototypes and pilot runs are produced internally. Volume production is outsourced to either a Tier 1, 2 or 3 EMS Company. Products are optics, electronics, sheet metal and plastics. Products produced in Monterrey and Juarez, Mexico; Shenzhen, China; Soul, Korea or Akita, Japan.

Managed production growth of this venture capital start up to annual revenue $50 million. Developed scalable high volume production and supply chain capability that resulted in industry leading product quality, cost and availability. This is a multi-plant/multi-country operation. Implemented QAD (MRP system). Negotiated contracts and price reductions.

Moved production from Raleigh, North Carolina to Monterrey, Mexico in a four month period while maintaining customer deliveries and ramping production (40% growth Qtr to Qtr). Implemented on-line test monitoring & support network between Monterrey, Mx and Atlanta. Able to obtain real time production and test yields with the ability to support production remotely.

Manage domestic, Mexico & off-shore (China) suppliers. Negotiated strategic sourcing contracts. Implemented VMI and Consigned Inventory practices. Initiated a supplier-rating program to improve supplier on-time delivery and part quality performance. Manage logistics for inbound and outbound freight (domestic and international). Reduced material cost >7% year over year by spend analysis, lean initiatives in the extended value stream, increasing responsiveness & improved quality.

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Dan Leveille page 2

Introduced lean manufacturing methods that reduced scrap and increased quality to “Best-In-Class” for Last Mile market segment products through root cause analysis and application of irrevocable corrective action. Implemented “pull replenishment” with casting supplier reducing inventory in supply chain 60% and On Time Delivery to 97%.

Manage “Arena”, a web-based Engineering Change Management system that immediately disseminates engineering changes and velocity of changes/responsiveness of supply base.

Raised inventory accuracy from 85% to +99% by initiating cycle count in raw, WIP and finished goods inventories. Implemented and attained ISO 9001:2000 certification in 9 months. Wrote/created 60% of the procedures and processes.

Vice President of Operations 1999 - 2002

Onkyo-America, Columbus, Indiana

http://www.onkyo.com/

Vice-President of Operations for Onkyo America a $72 million, Tier 2 QS/ISO 9000 OEM Automotive, After-Market and Consumer Sound System provider. Responsible for supply chain, production, materials, shipping & receiving, production control, new product introduction, quality (PFMEA/PPAP/APQP), environmental testing, manufacturing engineering, safety and facilities for a non-union 450 employee OEM Automotive plant.

Produced 36,000 units/day (35 million units/ year) making Just-In-Time shipments 4 times/day to 12 locations (Delphi (GM), Chrysler, Clarion (Nissan), Fujitsu-TEN (Toyota), Visteon (Ford), and JL Audio plants. Facility consisted of 139,000 sq ft and ran 2-shifts per day with bottleneck operations running 3 shifts per day. Process quality was <12-ppm process.

Facility contained 3 Injection molding presses, 150 ton to 500 ton (Cincinnati-Milacron) using polycarbonates and polyethylene. Secondary operations included hot plate welding, sonic welding assembly utilizing Poka-Yoke methods

QS 9000/ISO 9000 compliant, lean manufacturing (Toyota Production System), Six Sigma, Black Belt, KanBan driven facility. This was a make-to-stock production environment using EDI material management practices.

While at Onkyo-America, received Toyota-Supplier-Of-The-Year-Award for 100% on-time schedule attainment with zero defects (zero PPMs) on delivery 9 million units. Delivery was to a Just-In-Time (4 hour window) to the assembly plant.

Increased material turns from 10-16 while reducing material cost by 7% through VMI in place stores and implementation of lean practices into the supply base. The supply base was mainly China and Korea. Implementing lean practices into the supply base along with lean in daily operations reduced operating costs by $1.5 million annually.

Reduced scrap from 1.33% to 0.63% through quality Kaizen and Six-Sigma initiatives.

Director of Operations

Atlanta, Georgia

http://www.on-siteanalysis.com/

Director of Operations for On-Site Oil Analysis Company formally know as Global Technovations. A start-up company that produced state of the art diagnostics equipment for petroleum products. Products combined industrial, electro-optical instrumentation and tribology rules to produce easy to use analytical instruments for retail, industrial and commercial markets.

Responsible for purchasing, inventory, production, production engineering, testing, CE certification, facilities, human resources and field service. Worked with Customers, Sales and R&D to develop and implement product features (hardware & software) and attain product realizations. Was responsible for P&L of the Atlanta Operations.

Promoted to Vice President of Operations for Onkyo-America.

Manager, New Product Eng/Mgr. Test Engineering 1993 – 1999

Norcross, Georgia

http://www.sciatl.com/

Manager of New Product/Test Engineering for all Atlanta based business units at Scientific Atlanta. Scientific Atlanta was a $1.2 billion electronic communications operation. Responsible for manufacturing and test engineering aspects of the new product introduction process. Managed 61 people (41 engineers and 20 technicians) with a departmental operating budget of $5.2 million. Over the course of three years, reduced the departmental budget to $3.9 million and headcount to 46 people while maintaining the same level of development and support. The New Product Engineering Group supported both U.S. and Mexico production facilities. The U.S. facility was low volume high mix and the Mexico facility was high volume low mix (over 1 million units/year).

Developed manufacturing technology roadmap to coordinate manufacturing process development (both hardware & test) with R&D product roadmaps. Continuously updated the corporate Producibility (DFM)/Testability Guidelines, which were based on cost models.

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Test Engineering Manager, Managed Software Development, Hardware Development, Incircuit Test Development, Project Test Development, Preventative Maintenance, and Computer Integrated Manufacturing (CIM) groups. Reduced time to market by 47% over an 18-month period. As manager of Test Engineering, responsible for all technical aspects of the assembly verification process which accounted for 55% of all conversion costs of a $67 million budget for 8 main business unit product lines.

Planned and implemented operational strategy to transfer $20 million of annual revenue generating products from Atlanta to Juarez, Mexico. Implemented high volume production test lines (350,000/qtr in Juarez) for set top boxes.

Education

MBA Northern Michigan University

BSIT Northern Michigan University, Academic All American

CPIM Certification, American Production and Inventory Control Society (APICS)

MFGT Certification, Society of Manufacturing Engineering (SME)

QEIT Certification, American Society of Quality Control (ASQC)

Member of the Institute of Supply Chain Management (ISM)

ISO 27001 Certified Auditor

STAR IT Cloud Security Auditor

ISO 13485 Certified Lead Auditor

Lean Sigma Master Training/Certification (Japanese) – Onkyo-America – 2001

Problem Solving and Decision Making Skills – Kepner-Tregoe – 2000

Six Sigma Green Belt Training /Certification -- 2000

Effective Negotiation Skills Training – Karass – 1999

Executive Leadership Development Program – Strayer Group

Leadership Through Teamwork Management Training Program – Strayer Group

Quality Education Systems - Phil Crosby

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