Bill Roberts

** **** *** *****, **********, TX **402

ad5bn9@r.postjobfree.com

Primary Phone: 903-***-****

A successful professional with a proven track record of designing and implementing technical solutions to help improve operational efficiencies and capabilities, training, processes, and safety performance. Areas of expertise include:

●Lean Manufacturing – Toyota Performance Enterprise System

●Manufacturing Management & Supervision, Safety, Budgeting, Inventory Control, Staffing, Operations

●Project Management - Capital Equipment, Automation, Facility Expansion, Transfer Operations Overseas

●Front Line Leaders Skills Development/Team Building& Self -Directed Work Teams

●Training Development - Safety, Inspections, Behavior, Performance Improvements, Process methods, Quality

11/2014-Present

L3 Harris, Intelligence, Surveillance and Reconnaissance (ISR) Sector, 10001 Jack Finney Blvd., Greenville, TX.

Government Contract Facility for Aerospace Contracts

SENIOR MANUFACTURING ENGINEER with Secret Security Clearance.

●Developed floor plans for expansion projects for Harness Assembly, Console Shop, PWA and Black Box.

●Responsible for workstation selection, electrical and I.T. contractors for new development projects.

●Responsible for all aspect of tool control, selection, procurement, and toolbox development for Harness Shop.

●Lead an 8D project for standardizing tool control and toolbox layout designs.

●Lead many 5S+1 projects as the Facilitator

●Implemented many processes improvement projects to decrease quality defects. Received special recognition Quality Award. This was a quarterly award program for the facility of 6,000 employees with only 1 person recognized each quarter.

8/13- 4/14

PCHEM/Weatherford Engineered Chemistry - 936-***-**** or 936-***-**** Latexo TX 75849 contact Craig Turn

(A global specialty chemical manufacturer for oil and gas drilling operations.)

MANUFACTURING PLANT MANAGER

●P&L budgeting requirements. Develop & maintained budget or exceeded requirements with average operating expenses $700k per month with a plant size of 50 people.

●Safety administration support to ensure safety policies and practices are being followed and improve upon Process Safety Management Program. Focus on accountability for safety violations or incidents as a result of not following safety policies. Worked on better communication on safety items throughout the facility for consistency.

●Right size staffing for job functions and demand. Determined production staff requirement based on production hours required to forecast demand.

●Maintained Inventory turn of 12 or better. Reduced finished goods and raw material inventory by monitoring lead times and building on demand, (Typical 6-9 range). Raw material $3.4M to $2.6M.

●Review work order variances, standard cost and standard production times. 38-50% > +/- $500. Now <10%.

●Responsible for personnel development in Leadership, Manager skills, Production and Inventory using principles of Lean and APICS; Production and Inventory Control, Capacity Management, Resource Planning; Equipment, Staffing and Materials. These skills were also applied to the Maintenance Dept for PM and spare parts control. Set plant goals and expectations around performance. None of which were ever used before.

●Maintain positive attitudes and build team/leadership environment. Started Supervisor development program.

9/04- 06/13

Cytec Engineered Materials- 209-***-**** Greenville TX 75402. Contact: Duong Truong. Hr Mgr.

(A global specialty chemicals and manufacturer of carbon, glass, and Kevlar composite materials impregnated with resin selling to the aerospace industry)

GLOBAL TRAINING COORDINATOR & LEAN MANUFACTURING LEAD

●Organized 6 teams of 60 people to implement Lean Manufacturing projects based on Toyota’s Performance Enterprising System; 5S, Kaizen events, 7 deadly wastes, Value Stream Mapping, Flow Analysis, Standardize Work, Visual performance displays, & Andon signals.

●Develop training plan to ensure associates have the knowledge and skill required to implement and maintain Lean Manufacturing efforts, along with assigned follow-up efforts established by the teams.

●Project example: increased output from 15 yrd/hr to 21 yrd/hr & cut set up time from 37 hours to 18 hours by developing a value steam map, defining items that were internal & external to set up, defining best work practice, and developing work standards based on product type.

●Reduced change over from 4 hours to 2 hours and complete set up from 6 hours to 3 hours in another area.

●Eliminated paperwork, human error, and non-value duplication by utilizing computers with links to all necessary forms and configured formulas to perform all math calculations and duplication.

●Implemented Andon Signals thru out the plant to improve material pick-up and delivery process.

●Implemented display board tied directly into the machines to display machine run time to assist operations and supply chain teams with the production and planning processes.

●Worked with HR department to gain Training grant from Texas Workforce Commission (TWC) totaling $158K in 2010 and $300K in 2012 to fund skills and developmental training for employees at the site.

●Responsible for 7 supervisors, 4 Cell Leads, 5 managers, 252 operators and 60 Global staff for training development, reporting, professional growth, leadership development, new hire orientation, safety, etc.

●Developed and implemented a training process using a 7 step form designed for all learning styles; Adult Learning, Leadership, Assessments, Evaluations, etc.

●Developed and maintained the Taleo learning management system for job-specific and safety training to ensure compliance with AS9100 quality management system.

●Developed and implemented training materials and videos for safety and manufacturing operations training.

●Work with HR and department leaders in recommending and identifying training and development courses for salaried employees to enhance their skill set and improve organizational capability.

●Developed and presented all aspects of safety training PowerPoints and videos for New Hire, LOTO, Confined Space, Hazmat, DOT, Fire, Ergonomics, etc. to ensure compliance with OSHA and company’s requirements.

●Participated in accident investigation, review, and corrective action implementation programs.

●Developed Standard Operating Procedure for Security Personnel.

●Part of SAFE Team and training new people to the team on the behavior-based safety program.

●Performed weekly safety inspections to ensure OSHA, NFPA, process safety management, and compliance with company safety policies.

●Audit review of existing safety programs and updated to ensure compliance; LOTO, Confined Space, Respirator Training and Fit Testing, Process Safety Requirements, Emergency Evacuation drills, etc.

5/03-10/09

Owner - Laser Blast Laser Tag, Crossroads Mall, Greenville, TX.

I had 2 gaming arenas. Maintained payroll, staff, scheduling, budgets, inventory, advertising, business plan; all aspects of business while obtaining Master's Degree and took a job with Cytec.

3/89 - 9/02

Dallas Semiconductor/Maxim Integrated Circuits, 14460 Maxim Dr, Dallas, TX 75240. 972-***-****

Company produces encapsulated printed circuit board assemblies for the computer market, NVSRAMS, clocks, smart sockets, telecommunication devices, and components used in various types of equipment.

SR. MANUFACTURING ENGINEERING SUPERVISOR: (6/98-9/02)

●Directly responsible for the supervision of three Manufacturing Engineers, three Engineering Technicians and a Repair and Maintenance Supervisor with four Repair and Maintenance Technicians; projects, assignments, PM, equipment, etc.

●Set up an offshore assembly site and off-loaded module assembly operations to a Philippine sub-contractor. Developed offload plan that took 3 years and 4 different phases including setting up the manufacturing operations: employee and engineering training and overseeing the manufacturing build of qualification lots, and continuous assembly manufacturing engineering support. Responsibilities included scheduling the transfer of products and equipment, including negotiations with freight carriers for the entire move.

●Responsible for the engineering supervision of the Surface Mount Assembly area in addition to the Module Assembly operation.

●Personal process responsibilities included injection molding, metal stamping, forming, and plating, symbolization, screen printing, pad printing, off-set roll printing, encapsulation, dispensing epoxy, vendor selection, supplier auditing, and support for the Philippines operations.

●Process product responsibilities for potted NV-SRAM modules, PC clocks, and Smart Sockets. Develop assembly process including all documentation and assembly drawings.

●Set up lean manufacturing, Greenbelt Certification, 6 Sigma SPC data collection for these areas, and ISO 9000 requirements.

●Directly responsible for back-end assembly operation of encapsulation, component brand, visual mechanical inspection procedure, lead straightening equipment, material flow, bill of materials, PLC programming of equipment, vision systems, standard operating procedures, etc.

SUPERVISOR OF ASSEMBLY, ENGINEERING, and MAINTENANCE (8/89 - 6/98):

Acted as Assembly Engineering Manager in the event of the Managers absence or in meetings.

●Responsible for capital equipment selection, training, scheduling, cost analysis and process improvements, FMEA, 6 Sigma studies, and Component of Variation (COV) Studies.

●Directly responsible for 17 automatic and semi-automatic machines.

●Directly responsible for the assignments, supervision and actions of six Engineering Technicians.

●Responsible for the direction of four Repair and Maintenance Technicians when in my work area.

●Responsible for vendor selection, inventory control, process materials, and spare parts for equipment.

●Automated highest volume of product to do 50% of the assembly operation increasing the average monthly throughput from 160 UPH (units per hour) to over 1200 UPH. Responsible for material planning, scheduling production and cost control of auto-assembly of all three shifts that ran 24/7.

●Automated component symbolization and inspection process increasing throughput from 750 to 2500 UPH.

●Automated our first fill encapsulation and component insertion resulting in monthly savings of $20K.

ASSEMBLY PRODUCTION SUPERVISOR AND SAFETY CORDINATOR: (3/89- 7/91)

●Responsible for the production supervision of the solder lines on all three shifts. Directed the actions of three Foremen.

●Doubled throughput of highest volume product by changing assembly method.

●Determined production schedules to meet the demands of planning.

●Increased departmental hourly throughput by 30% and reduced headcount by 25% the first year.

●Determined production standards for solder lines.

●Developed an employee hourly average through-put report using Maxcim Management Information Systems.

●Developed chemical handling, waste management program.

●Developed assembly safety training & inspection; PSM, Haz-Mat Teams, ER Team, and Fire Brigade.

●Responsible for compliance to Haz-Com Act 1910.1200 and safety programs in assembly area.

1/88 - 3/89 E-Systems/ L3 Communications, 903-***-**** Greenville, TX

MANUFACTURING ENGINEER, PCB ASSEMBLY:

●Designed and implemented floor plan to decrease material flow distance by 75%, (4260ft).

●Used hands-off approach that reduced cycle time by 53%. High volume products from 50 to 6.5 hrs.

●Originated and developed Detail Manufacturing Instructions; still used today.

●Determined kiting of components method and analysis.

●Responsible for capital equipment evaluation assembly tooling & fixtures

●Programmed surface mount equipment, component locators, and water jet.

●Formed a Process Control Assembly Team to improve assembly methods.

1/87- 8/87 Nu-Kote International (formerly Burroughs), Bardstown, KY

PRODUCTION SUPERVISOR, ERGONOMIST AND SAFETY CORD: (internship developed to supervisor position)

●Responsible for the production of 50 employees and overtime personnel for injection molding, metal stamping and forming, assembly, and packaging.

●Designed workstation setups that increased production output to as much as 50% on some devices and reduced the number of carpal tunnel syndrome cases.

●Developed Haz-Com Program, Ergonomics Committee, and Safety Team

College Summers Williamette/Dotmar Paper Mill, Hawesville, KY

EDUCATION

●5/2006 Texas A&M University- Commerce, TX

Master of Science in Business Organization & Training Development

●12/1987 Murray State University- Murray, KY

Bachelor of Science in Safety Engineering and Industrial Hygiene

●American Production & Inventory Control (Basics of Supply Chain Management, Production & Inventory

Control, Capacity Analysis, Master Planning of Resources)

●Lean Manufacturing – Toyota Performance Enterprise System

●Film Training - 40 hrs from The Travel Channel

●PLC Programming - General Electric

HONORS & ACTIVITIES

U.S. Patent #6,191,955, Encapsulation and enclosure of electronic modules. (Dallas Semiconductor) http://www.google.com/patents/US6191955

Received special recognition letter of appreciation from Dave Snyder; VP of Operation at Cytec, for doing a Safety Video and was requested to share it with all the Cytec sites.

Cytec published an article presented in the corporate Cytec Courier on my work for Cytec's training program.

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