Six Sigma Engineer

Eng. Alejandro J. Morales-Harrison

PMB Box ***, Palmas Inn Way, Suit 130 Humacao PR, 00791 Phones: 787-***-****, 787-***-****

SUMMARY

Engineering and Operational Excellence professional with over 15 years progressive experience in Fortune 100’s in

electronics, automotive, medical devices and bio-engineering industries. Experience in business process management,

continuous process improvement, global programs deployment, and team leadership. Results and oriented and continuous

improvement mindset.

PROFESSIONAL EXPERIENCE

MEDTRONIC, Juncos, PR

(World leading Medical Devices Company with revenue over $15B)

Business Excellence & Engineering Manager

& Lean Six Sigma Sensei (Sensei = master of masters) October 2009-Present

• Develops, coordinates and drives the Engineering & Operational Excellence “OpEx deployment plan in Manufacturing

and Business Process.

• Directly supports the OpEx & Engineering needs of the Global High Volume Facilities “HVF Operations.

• Coaches, develops and mentors a team of engineers, indirectly all facility managers and cross functional engineers and

technicians toward projects execution (IT, Facilities, EHS, Industrial Engineering, Security, Lean Projects and

Maintenance). Coach Engineers to ensure their continued development in areas such as Six Sigma and LEAN in

addition to meeting Industrial Engineering and plant business goals and objectives.

• Assists senior leaders and champions in selecting projects that align with business/functional goals and

strategies/tactical.

• Works with leadership in installing organizational supports for Operational Excellence (reviews, communications,

rewards, systems (work standards, etc.)

• Drives high level engineering activities through team.

• Leads the development, implementation and overall management of overall improvement processes that incorporates

Six Sigma, Lean and Engineering tools.

• Manage $2.5MM budged and $4MM capital projects.

Engineering Manager & Lean Six Sigma Deployment Leader for all Puerto Rico Operations

& Lean Six Sigma Master Black Belt Nov 2004-Oct 2009

• Established engineering strategies, projects objectives and assignments for Process Engineering and,,technicians to

achieve organizational goals.

• Involved in developing, modifying, and executing company policies that affect immediate operation(s) and may also

have company-wide effect.

• Assured all equipment maintenance are performed as planned, all Health, Safety and Security policies / procedures are

complied

• Effectively led and facilitated mfg and plant projects, i.e. mfg capacity assessment and solutions, process capability

analysis, make vs. buy decisions, material changes and cost impact process. (Creativity before capital). Managed

$2MM budged.

• Developed organization in Lean Manufacturing and Six Sigma tools to solve problems and get sustainable results.

• Effectively manages capital assets.

• Understands how to navigate through the organization and protocols to get things done.

• Able to negotiate to satisfy multiple objectives and create win/win solutions.

• Shared resources, best practices, and time across the organization.

• Solicits input from all stakeholders to achieve consensus.

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• Makes decisions in the best interest of the team & organization.

• Communicated and influences effectively at all levels of the organization.

• Developed an environment of shared responsibility, empowerment, and ownership

Lean Sigma Master Black Belt Oct 2002 – Nov 2004

• Led/Managed continuous improvement system/projects from concept to full implementation and coordinate all

activities required.

• Facility and coach multiple continuous improvement teams in business process, product development, and

manufacturing.

• Conduct project reviews, specifically after the Analyze phase, to ensure validity analysis, and Control phase to ensure

sound control plans.

• Continuously identify areas of improvement in both product and process and assist in project pipeline development to

determine appropriate scope and defining reporting metrics

• $5.9M in saving during the since program start as results of the successful integration of several Six Sigma Projects.

• Integrate Lean concepts in key business areas resulting in above $4M in savings and averaged 40% in productivity

improvement.

• Lead & Support business objectives to achieve AOP goals and metrics development

• Nominated the Lean and Six Sigma Integration Team resulting in 2 CRM starts of excellence awards.

MOTOROLA, Boynton Beach, Florida

(Then World leader in Telecommunications and Semiconductors products with sales over $39B)

Sr. Staff Development Engineer & Six Sigma Black Belt

Personal Communication Sector, July 2000 – October’2002

• Managed Six Sigma Black Belt initiatives and lead Design/Product/Process Productivity Improvement efforts

• Simulation, CAD modeling, and design using Pro/Engineer ®

• Led actions plans to drive six sigma solutions on product field issues and warranty improving bottom line results by

30%

• Managed cost reduction efforts on wireless handsets devises resulting in saving of $800,000/year

• Improved reliability and performance of wireless handsets portfolio resulting in over 80% defects reduction on critical

product.

• Negotiated and managed outsourced product and process to drive major’s issues and improve productivity.

• Deployment of Breakthrough Six Sigma methodologies and system for manufacturing, product design, and service

(Business) improvement

• Mentored, consulting and Train Executive Green and Black Belts candidates at the different corporate sides (Brazil,

Mexico, USA, and China). Mentored 32 GB and 5 BB candidates worldwide. Certified 12 GB and 3 Black Belts.

UNITED TECHNOLOGIES Automotive Division, Tampa, Florida

The most admired aerospace company with net income of $1.93B

New Product/Process Staff Engineer January 1999 – July 2000

Support day-to-day manufacturing operations, led process improvement initiatives, and managed new product introductions

• Implemented and drove the engineering support strategies to provide world-class capabilities in manufacturing

operations via LEAN and TOC methodologies. Resulting in a reduction in defects of over 40% and cycle time

improvement of 20% on one of the critical high runner products.

• Led new process, new technologies Design for Manufacturing (DFM) initiatives to ensure successful product launch.

• Led FMEA program. Responsible for the development, implementation, and training of Professional and technical

staff. Reduce RPN on critical work cells from 2500PPM to <50PPM and 100% training compliance resulting in overall

process/equipment improvement

LUCENT TECHNOLOGIES, Piscataway, New Jersey

Bell Lab Innovations

(Then the industry’s most completed wireline portfolio)

Process/New Product Launch Staff Engineer March 1998 – January 1999

Led process and product improvement initiatives, and new product introductions

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• Developed new Surface Mounts Process using Six Sigma methodologies for handsets devises resulting in over 60%

efficiency improvement when compared with similar existent lines.

• Led new products introduction reviews with specifics spec goal toward defining process parameters

• Led efforts to determinate initial setup and configuration of equipments and process including the appropriate

hardware and software documentation.

• Led Design for Manufacturing (DFM) initiatives to ensure successful product launch

MOTOROLA, Vega Baja, Puerto Rico 1993-1998

(Then Motorola’s Largest Manufacturing Plant with shipments of over 1 million units per month)

Manufacturing Engineering Group Leader, Paging Products Division June 1996 - March 1998

• Managed engineering and technical resources to support the day-to-day manufacturing operations

• Managed Six Sigma Process Improvement Methodologies resulting in 68% defects reduction per year

• Reduced equipment downtime by 25% per year by achieving 100% maintenance compliance via TQM and TPM

methodologies.

• Managed the 1997-1998 Yield Improvement & Cost Reduction program with over $4M in cumulative savings.

• Mentored the Process & Equipment Characterization and Optimization Program via Six Sigma and DMAIC model

(then MAIC model) for all critical processes and equipments.

• Managed directly 8 Engineer, and 12 Technicians.

• Managed the Quality System Review Process to obtain a qualified score in Subsystems responsible.

Senior Manufacturing and Project Engineer, Paging Products Division April 1993 – June 1996

• Led new product introduction, conducted process and equipment improvement through Six Sigma methodologies and

DMAIC (then MAIC) business improvement model

• Led new products introduction and design for manufacturing (DFM) activities.

• Performed process and equipment optimization and characterization via Six Sigma Methodologies

• Reduce cycle time on critical products by over 20% and achieved defect reduction by 30%

EDUCATION

College of Engineers of Puerto Rico, Hato Rey, PR

Certified Lean Sigma Sensei, November 2010

Medtronic World Headquarters, Minneapolis, MN

Certified Lean Sigma Master Black Belt, October 2004

Motorola University, Schaumburg, IL

Certified Six Sigma Black Belt, December 2001

Certified Six Sigma Green Belt, June 2001

Major: Continuous Improvement Strategies and Statistics Methods

Polytechnic University of Puerto Rico, Hato Rey, PR

Master in Engineering Management (MEM), July 1997

Major: Operational Manufacturing

University of Puerto Rico, Mayaguez Campus, PR

Bachelor of Science in Mechanical Engineering (BSME), May 1993

Major: Machine/Mechanical and Thermal Design

PROFESSIONAL DEVELOPMENT

Project Management Certification Program (Kerzner Approach)

Problem Solving and Decision Making (Kepner-Tregoe)

High Tech Process and Equipment Train-the-Trainer

(Certified by Motorola University and Panasonic Factory Automation)

Licensed Engineer in Training, Puerto Rico Board of Engineers

Member of: American Society for Quality (ASQ).

Reliability Engineering Journal and Six-Sigma Forum.

Active Member of the College of Engineers and Land Surveyor of Puerto Rico

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ADDITIONAL SKILLS

MS Office, Project Tools (Microsoft Project)

Supplier Qualification

Safety and Environmental Regulations

ISO & FDA Regulations

21 Code of Federal Regulations (21 CFR)-Medical devices Industry

Minitab 14 & 15 & JMP statistical package

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