Six Sigma Engineer

GENE NADELSON

** ********** *** **********, ** **039 718-***-**** *********@*****.***

Strategically thinking, goal-oriented quality leader with over fifteen years of experience in Fortune 500

companies. Data-driven Lean/Six-Sigma Master Black Belt with superior continuous improvement and process

re-design skills in a team-based environment. Lead-by-example leadership style with focus on results and team

development.

PROFESSIONAL EXPERIENCE:

LTS, West Caldwell, NJ 2012 – Present

Associate Director of Production

Establish and rollout Operational Excellence Program. Report directly to the Vice President of Production.

Responsible for all technical aspects of manufacturing operations, including waste reduction, process

improvements, performance management, goal setting, project execution, policy deployment.

• Re-organize Print-and-Pouch department. Establish clear promotional criteria for operators. Introduce Senior

and Lead Operator positions.

• Modify corporate bonus structure by introducing measurable goals for the entire organization.

• Provide technical leadership and expertise to the entire organization on process, manufacturing and

engineering related issues and drove continuous improvement efforts within the workforce through mentoring

and coaching.

• Develop and monitor a scorecard of metrics to ensure that key manufacturing and operational goals were met.

• Established and successfully rolled out Autonomous and Preventive Maintenance programs.

• Establish quarterly OE knowledge sharing sessions between sites to improve overall performance.

Genzyme, New York, NY 2007 – 2012

Associate Director of Six Sigma and Lean 2010 – 2012

Leading the Six Sigma and Lean initiative for the Genzyme Genetics Division.

• Developed strategy and approach resulting in Lean implementation into business processes and

operations.

• Lead the development and implementation of $1.2M conversion project, resulting in full implementation

of Lean Techniques in the clinical laboratory environment, resulting 50% reduction of the Turn-Around-Time

and annual cost savings of $500K.

Senior Program Manager (Six Sigma Master Black Belt) 2007 – 2010

Launched Six Sigma program across all sites and functions of the Genzyme Genetics. Developed strategy and

deployment roadmap for Six Sigma. Lead project teams consisted of employees from various levels within the

organization, from Site Director to hourly employees. Ensured successful completion and certification of Green

and Black Belt projects.

• Lead a cross-functional team through the design of a global process to enable the division to strategically

position its testing facilities, resulted in shipping cost reduction over $1.0M.

• Lead the selection of the Six Sigma/Lean Green and Black Belt Training materials, performed division-

wide trainings, mentored Green and Black Belts.

Pfizer, Inc, Brooklyn, NY 2003 – 2007

Senior Financial Project Leader 2006 – 2007

Spearheaded roll out of Six Sigma and Lean in the Finance Department of the Pfizer Manufacturing Plant.

• Spearheaded all financial analysis and estimated all costs, related to the site-closure and all product transfers.

• Developed cost improvement initiative resulting in annual savings of $50,000.

• Reduced budget preparation time by 50% to one month, by utilizing Lean principles and Six Sigma analysis.

• Performed monthly forecast and variance analysis of Direct Expense System totaling over $50M.

Six Sigma Project Leader (Certified Six Sigma Black Belt) 2004 – 2006

Managed all aspects of Six Sigma implementation in the Solid Dosage Manufacturing area. Lead site-wide

Product Based Capability Analysis Team, which identified over 30 Six Sigma improvement projects.

• Successfully led cross-functional Green and Black Belts Six Sigma project teams resulted in annual

savings of $1M in the manufacturing area.

• Managed implementation of the Root Cause Analysis Team that reviewed site-wide investigations and recommended

Corrective Actions, resulted in 90% reduction of the open investigation.

• Completed over 100 quality investigations (CAPA’s) related to the manufacturing area, resulted in annual savings

exceeded $1.5M

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Quality Compliance Specialist 2003 –

2004

Introduced Six Sigma tools for the completion of the process and product related investigations. Lead

investigation teams to resolve out-of-compliance matters. Resolved quality issues related to manufacturing area

of the solid dosage manufacturing plant.

• Reduced QC Testing Time, by 30% by validating and implementing an automated tablet testing system.

• Modernized investigation program by introducing Six Sigma tools. Reduced investigation time by 60%.

GlaxoSmithKline, Clifton, NJ 2002 – 2003

Operational Excellence Expert (Six Sigma Black Belt)

Lead projects to deliver improvements in the toothpaste manufacturing facility.

• Designed and managed Lean Manufacturing / Six Sigma Program resulted in 30% reduction of the cycle time.

• Optimized filling process by utilizing DOE technique, resulted in process yield improvements of 35%

Stryker Howmedica Osteonics, Allendale, NJ 2001 – 2002

Quality/Validation Engineer (Contract)

Validated manufacturing equipment in the implant manufacturing facility. Established, reviewed and approved

manufacturing SOPs.

• Implemented Lean tools at Quality Department resulted in improved quality practices and minimized mistakes. Reduced

gauge calibration time by 80% to 0.5 days.

• Optimized sterile packaging process with Taguchi DOE techniques resulted in annual savings of over $80K.

Pall Medical Corporation, East Hills, NY 2000 – 2001

Project Engineer

Spearheaded and completed global SPC implementation project.

• Achieved 30% yield increase by utilizing SPC.

• Qualified and validated equipment/process for automated manufacturing system for blood filters

assembly.

• Performed Reliability Analysis for the automated manufacturing line, reaching daily downtime less then 5%.

Aircast Inc., Summit, NJ 1998 – 2000

Manufacturing Engineer/Production Supervisor

Supervised 25 assembly line operators on 2-shift operations. Oversaw shift operations to ensure smooth

functioning facility and high yields. Reviewed production and yield data to identify improvements .

• Developed and implemented SPC program to correct manufacturing process and achieved daily yields above

90%, within first year of production.

• Implemented Flow Control Manufacturing resulting in a 15% inventory decrease.

PowerTech Inc., Fair Lawn, NJ 1996-1998

Process Engineer

Supervised 10 employees in the transistor-manufacturing department: formally evaluated each employee’s

performance.

• Achieved 30% yield improvement, by optimizing existing manufacturing processes, using Statistical Process

Control.

EDUCATION:

BARUCH COLLEGE, New York, NY

Master of Business Administration in Operations Management and Finance

THE CITY COLLEGE OF NEW YORK, New York, NY

Bachelor of Engineering in Electrical Engineering

OTHER SKILLS:

Fluent in Russian, Six Sigma/Lean (Master Black Belt), DFSS, DOE, SPC, SAP, cGLP/cGMP and FDA

Regulations, Lean Manufacturing, Validation, Theory of Constraints, Kepner-Tregoe, Project Management,

Minitab, MSVisio and eVSM.

PROFESSIONAL AFFILIATION:

• Performance Excellence Examiner, Massachusetts Quality Award (Baldridge Excellence Program)

• Senior Member, American Society for Quality (2000-Present)

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