Director Injection Molding

Steve Jacobs

Home 239-***-****

**** ** ****** ******* ****

Cell 239-***-****

Cape Coral, FL 33914

*******.*****@***.***

VISION

To strive for efficacy in my daily life, to get more done in less time and

to enjoy the process along the way. To experience more fulfillment and to

create more value in my life as well as in the lives of people around me.

SUMMARY

Experienced hands-on operations, engineering and tooling manager with a

full knowledge of manufacturing, automation, reducing costs, securing the

supply chain and establishing safe manufacturing practices. Experienced in

the plastics and metal stamping industries including injection molding,

transfer and compression machines and processes, materials, tooling, design

engineering, line installation, facility construction and equipment

allocation and relocation. A solid background in global sourcing,

application and project management procedures, technology transfer, and

team building. Solid and extensive background in computer hardware and

software. More than 50 projects, Six Sigma and Lean Manufacturing that have

increased efficiencies, increased productivity, reduced waste and resolved

EHS issues.

SKILLS

. Industries include plastic, metal stamping, telecommunication,

electronics, medical, high technology, consumer products, automotive and

military.

. Capabilities include customer interaction and satisfaction, analysis and

problem solving, troubleshooting, planning and organizing, continuous

improvement, scheduling and meeting deadlines, establishing Best

Practices and Lessons Learned, developing and initiating training

programs and 5S.

. Work expertise includes plant management, managing the supply chain, team

building, P&L and budgeting, Six Sigma Black Belt, Lean Manufacturing,

materials management, project management, sales and marketing, writing

protocols and validating IQ/OQ/PQ, Scientific Molding, SMED, DOE, DFMA,

NPD, NPI, ISO/TS, cGMP, FDA and EHS

. Personal capabilities include imagination and creativity, assertiveness,

leadership, mentoring and coaching

EXPERIENCE

2006-present, Forensic Analyst and Manager

Increasing the bottom-line utilizing DOE's, capability studies and

scientific (decoupled) molding to validate new tooling and the molding

process, Developing and writing procedures, training and leading molding

technicians, SMED team, engineering, production and maintenance personnel.

. Decreased mold set-up times 52% by reorganizing the SMED team, training

and eliminating waste. Saved $242K

. Decreased DPPM 71.3% and scrap 53% by training technicians in proper set-

ups and troubleshooting techniques.

. Decreased maintenance down-time 37% by establishing planned proactive

maintenance and utilizing thermal imaging.

. Increased OEE 20.3% by decreasing DPPM and increasing utilization. Saved

$2.2 million annually.

. Wrote 2 books about molding and setting up a process window,

troubleshooting and product design.

2004-2006, Corporate Process Manager/Molding, Guardian Automotive

Responsible for guiding and implementing new technology, Best Practices,

Lessons Learned and safety programs throughout the company's $460 million

molding facilities. Ensured product designed for manufacturability and tool

build.

. Implemented a scientific approach to injection molding resulting up to a

30% cycle time reduction and an improved quality yield.

. Increased the yield of one specific product by placing the correct

equipment in place. This eliminated over $1,000/day in scrap.

. Responsible for mentoring managers, engineers and technicians in 6

facilities in 4 States.

. Increased customer's satisfaction rating by resolving a plating problem

in 4 weeks that had been plaguing the company for over 3 months prior and

at a revenue loss of $1.5 million.

2001-03, Engineering Manager (AEM), Medsource Technologies

Establishing the supply chain, implemented and debugged proof-of-concept

through manufacturing of electro-mechanical medical devices and mold

validation for top medical companies. Revenue from one customer increased

40% year over year.

. Set-up a team that reduced a bipolar surgical instrument's high pot

failure rate during assembly from 13% to under 0.05%. Result of this

project reduced a $375K annual scrap rate to under $200. Payback: 1

month.

. Defined the scope of new products and implemented proof-of-concept,

design and manufacturing of medical devices and assemblies. Major markets

included cardiovascular and gynecological surgical instrumentation.

. Increased speed-to-market with new medical devices by decreasing 18

months standard entry to 6 months by setting-up an office in the

customer's facility and working alongside their engineers and managers to

provide continual support of their marketing, R&D and sales efforts.

1996-01, Manufacturing Manager (Manager Fabrication/Sourcing), General

Electric Company

Led a team and managed the P&L of the fabrication and supply chain of over

1,000,000 precision electro-mechanical plastic and metal components daily

for a multi-site (US and Mexico) operation; directing two tool rooms,

production control, purchasing, scheduling, warehouse, maintenance,

engineering, quality, automation development lab and safety.

. Cut costs and generated significant annual savings in labor by increasing

efficiencies 17% on a 30 year old product by reducing cycle waste:

productivity rose 23%.

. Decreased overdue shipments 13% in 4 weeks by implementing daily

production meetings and resolving potential delays: on-time delivery

increased 100%.

. Set-up a team that implemented Kan-Ban on-line in 3 weeks for over 2,000

items. Reduced WIP 25%

. Reduced raw material inventory $500K in 2000 by negotiating contracts

with vendors and redesigning a product to use a less expensive material

without a sacrifice in quality.

. Implemented a fabrication technology transfer and design modification for

a switching cam: output increased 300%.

. 10% VCP year over year by redesigning the product, using less expensive

materials and incorporating deflationary negotiations with vendors

. Set-up and mentored a team that improved warehouse shipping accuracy to

99.99% by using scanners.

. Redesigned a MRP reporting system and replaced a 4-7 day lag into real-

time reporting to create more accurate information and eliminate material

run-outs at assembly.

1985-96, Director/Engineering, Shoreline Tool and Engineering

Implemented new technology, product development and a global supply chain

for fortune companies that included J&J, Sanmina-SCI, Black & Decker,

Velcro, Warner-Lambert, GM, CBS, and RCA. Conducted feasibility analysis

and total project planning for new technologies. International sourcing of

plastic and metal stamp tooling, plastic components and metal stampings,

and assemblies.

. Developed the plastic in situ hook for Velcro when their textile hook and

loop patents expired by incorporating a technology transfer from woven

textile to plastic injection molding. Generated millions of dollars in

added revenue. Built a factory to produce this new product on schedule

and within budget.

. First in the industry to develop a mold bleeding system that eliminated

EHS issues during mold changes.

. Set-up the first plastic's degree granting program in Connecticut in 1994

to overcome a shortage of engineers in the industry. Wrote a manual and

taught the first class. Program set-up was completed on schedule and

within budget.

1981-85, Tooling Engineering Manager, Norelco, Philips Park Division, N.

American Philips Corporation

Provided tooling, plastic engineering and fabrication of electronic

consumer items for a $250 million division of NAPC. Facilities planning,

expansion and global sourcing for tooling, fabrications and assemblies.

. In 4 months doubled in-house capacity by adding more equipment, within

budget and on schedule, producing a 45% ROI the first year and an annual

cost avoidance of $500K.

. Set-up a team that turned around a $1M loss into a $1M profit in 8 months

by reducing scrap and increasing cycle efficiencies

. Saved $180K and reduced the lead-time 25% by implementing an alternative

approach to sourcing production tooling.

1979-81, Engineering Supervisor for Mold Design, Texas Instruments, Inc.

Hired as a Manufacturing Engineer and promoted in less than a year to

Engineering Supervisor providing mold designs and engineering changes for

60 in-house mold makers and a global operation from 4 mold designers.

Budgeted and established the supply chain for outside tooling, components

and services. Managed a $1,000,000 outside tool design and build budget.

. Increased capacity 1400% by transferring thermoset connector fabrication

to thermoplastic molding. This resulted in having one person do the job

of 8 operators in a fraction of the time.

. Designed and programmed a computerized tracking schedule and maintained

an average of 125 weekly jobs for new product and engineering

development, existing engineering changes, new mold designs, outside

quotes, and in-house and external building of molds. Molds and mold

designs sourced globally.

TRAINING

Molding, University of Lowell; Management for Quality Control Supervisors,

University of Rhode Island

Screw Design and Rheology, Texas Instrument; Emergency Response, OSHA

29CFR1910.38; 120q/EPA 40CFR265.30-37,50-56,112 LAW Environmental; Spill

Prevention, Control & Countermeasures and Hazardous Waste Contingency, EPA

40CFR112, LAW; Lockout/Tagout of Energized Sources, OSHA 29CFR1910.147, LAW

Environmental; Basic Radiation Protection & Awareness, EPA 10CFR1910.834,

LAW Environmental; Access Data Base, Forms and Reports, ExecuTrain

Microsoft Certified Systems Engineer, Microsoft Technical Education Center;

Materials Management Global Inventory Planning, General Electric; Six Sigma

DMAIC, General Electric; Six Sigma Green Belt, General Electric; Six Sigma

Black Belt, General Electric; DOE, Guardian and RedX, GM.

Speaker and trainer in industry and various trade society groups

AA, Worcester Jr. College, Worcester

BA, University of Massachusetts, Amherst

MBA Program, Clark University, Worcester

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