Six Sigma Engineer

James Collins

**** ******* ***** **** *****, North Carolina 27265

336-***-**** ***************@*****.***

SUMMARY

A logical, innovative operations leader with extensive experience in process improvement, Six Sigma,

project/process engineering, continuous improvement, quality control, product development, budgeting,

lean manufacturing, production engineering, supplier management, and training/development. Uses

strong analytical skills and interpersonal abilities to set strategies to build a culture of achievement,

ensuring the ongoing enhancement of processes and continuous prosperity. A driven professional who

exceeds established corporate goals, making lasting contributions to the success of an organization.

EXPERIENCE

MANNINGTON MILLS High Point, North Carolina

2006 2012

Operations Manager

Oversaw manufacturing operations of wood plant, setting objectives for departments to align with corporate goals for

facility. Directed activities and objectives for department managers/shift supervisors, including performing annual reviews.

Set and managed financial budget as well as raw material, WIP, and finished goods inventory levels. Led continuous

improvement and cost reduction initiatives to achieve goals. Implemented lean manufacturing methodologies to improve

flow, reduce waste, and improve customer service levels. Interacted with key suppliers/customers to foster partnerships

and resolve issues. Managed multi cultural workforce, creating an environment that responded quickly and positively to

changing demands. Worked closely with all areas of organization (marketing, human resources, and research and

development) to provide communication to direct/indirect reports on plant and corporate results.

Fostered safety minded culture and emphasized product quality and customer expectations.

Directed operations of engineered wood flooring production facility with $100,000,000 in sales. Oversaw ten

salaried/200 hourly staff.

Led improvement initiatives in multiple departments, resulting in over $8,000,000 in savings through 10% annual

throughput increases and yield improvements.

Re focused culture to improve safety performance. Reduced total safety incidents by over 67% and decreased

lost time accidents to zero for past three years.

Improved plant quality focus, reducing customer claims by over 80% to historically low levels. Maintained best in

corporation service levels of over 99% combined with highest finished goods inventory turns.

Implemented lean manufacturing tools and methodologies to reduce inventories throughout value chain by

$5,000,000, decreasing changeover times by 70% and shortening average run size by 75%.

Established and managed annual spending budget for plant operations.

2002 2006

Continuous Improvement Manager

Created new continuous improvement department and set direction for initiatives. Integrated Six Sigma, lean

methodologies, and best practices into operation. Used Kaizen and Six Sigma tools to drive new product development.

Communicated with key raw material suppliers and addressed quality issues. Implemented permanent fixes to reduce

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problematic areas of customer complaints. Managed process engineering and quality for 250 employee facility with over

$100,000,000 in sales. Developed new continuous improvement department and set direction for departmental initiatives.

Generated Six Sigma Green Belt program for facility, including training material.

Redesigned process control and quality systems throughout facility to integrate Six Sigma and lean manufacturing

methodologies as well as best practices.

Reduced total customer claims by 50% during production growth of over 50%.

Led investigation resulting in recouping of over $6,000,000 in customer claims and losses from raw material

vendor.

Used Kaizen and Six Sigma tools to lead initiative for successful launch of product line, increasing sales volume

10%.

ADDITIONAL EXPERIENCE

AVERY DENNISON, Painesville, Ohio, Six Sigma Black Belt, 2001. Used Six Sigma DMAIC tools to achieve cost savings

on projects. Provided Six Sigma Green Belt training/support. Interacted with raw material suppliers and performed joint

projects for new product development. Managed cost reduction projects using DMAIC methodology from divisional

support function. Eliminated defect costing company $1,000,000 in scrap and customer complaints, improving supplier’s

process with new version of product to generate additional $450,000 annual savings passed on to company. Trained two

waves of Green Belt candidates.

Plant Technical Manager, Engineered Coatings Facility, Mentor, Ohio, 2000 2001. Oversaw quality, process engineering,

project engineering, and maintenance departments for facility with $10,000,000 in sales. Implemented Six Sigma

concepts, resulting in reduction of scrap and losses by over 35% . Led process improvement. Set objectives for direct

reports. Communicated with suppliers/customers to resolve quality issues. Worked closely with marketing/R&D to launch

products. Managed department budgets. Trained Green Belt wave. Set objectives for seven direct reports.

Six Sigma Black Belt, Painesville, Ohio, 1998 2000. Managed cost reduction projects. Introduced and fostered Six Sigma

methodology as part of initial wave of Black Belts. Taught four waves of Six Sigma Green Belts, mentoring cost

improvement projects. Developed Six Sigma Green Belt training materials. Implemented processes for completed

projects to turn over to manufacturing operations. Generated over $1,000,000 in savings from projects relating to

manufacturing scrap reduction/capacity improvement. Wrote and taught Green Belt training application modules

pertaining to capital project execution and project management.

Senior Process Development Engineer, 1993 1998. Completed projects for process/product development. Managed

capital projects, including key position on $10,000,000 addition of processing line/supporting equipment. Worked closely

with raw material/equipment suppliers. Communicated with teams for product development. Achieved Technical

Directors’ Award for contributing to $10,000,000 capital project team, acting as product developer for cross functional team

transitioning $10,000,000 in sales of product between facilities, and serving as process developer for cross divisional team

to develop novel capabilities/scale up for product launch of battery label product.

Process Engineer, 1990 1993. Coordinated daily issues for product lines of $20,000,000 facility as sole process engineer.

Managed scrap reduction and capacity improvement projects. Oversaw small capital projects. Communicated with

multiple departments across organization. Led capital project for new $100,000 gauging system.

EDUCATION

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UNIVERSITY OF AKRON, Akron, Ohio

B.S., Chemical Engineering, 1990

CERTIFICATION

Six Sigma Black Belt, 1998

COMPUTER SKILLS

Microsoft Office Suite, SAP

PERSONAL

Married. Enjoys running, backpacking, and volunteering.

Contact this candidate