Six Sigma Quality

RAJESH SOLANKI

*** **** ***** **** ********, PA *5108

330-***-**** Mobile 412-***-**** Residence ******.********@*****.*** http://www.linkedin.com/in/rajeshsolanki

Senior Leader with a track record of successful Lean Six Sigma strategy deployment, commitment to Operational

Excellence and elevating quality performance across an organization. Quality Excellence Leader and Lean Six Sigma

Deployment Champion highly skilled in quality and operations management, business process re-engineering, lean product

development, supplier development, quality management systems and outsourcing initiatives on a global scale for world-

class companies.

Increased savings from $3M in 2005 to $33M in 2008 (vs. $18M goal) by driving LSS process improvements.

Led initiatives to reduce COGS and SG&A while enhancing margins and quality KPI’s. Stabilized current state; matured

teams to implement Value Stream Transformation based Quality Systems across entire supply chains.

Successfully built 3 Quality and LSS organizations from concept for Fortune/Global 500 companies.

Developed and managed teams in North America (U.S., Canada, Mexico), Asia (China) and NZ/Australia

supporting businesses to $2.5B annual revenue and 14,000+ associates worldwide.

Played a key role in post-acquisition transition and integration of assembly/sourcing operations.

Facilitated 20% cost savings by relocating component manufacturing to maquiladora.

Effectively transferred tribal knowledge and maintained product quality in the transition.

Offers a methodical approach to foster process improvements and eliminate long-standing quality issues.

More than tripled revenue per team member by developing robust pipeline of quality projects.

Reduced cash flow requirements $34M through inventory reductions by Value Stream Transformation initiatives

including flow manufacturing and visual management.

Strategically positions organizations for critical change while structuring unified organizations for continued success.

Instrumental in doubling profitability (to 14%) through quality management and reductions in process variations.

Consistently identified and groomed as high-potential candidate for senior management tracks.

PROFESSIONAL EXPERIENCE

RTI International Metals, Inc, Pittsburgh, PA Oct 09 – Present

Corporate Director, Continuous Improvement

- Recruited to implement RTI Production System enterprise wide with full business process integration.

- Assess lean and six sigma competency across 8 business units globally (US, Canada, UK, France) to

develop CI Specialists and Master CI Leaders

- Lead Continuous Improvement initiatives across Boeing 787 Dreamliner Pi Box value chain to increase

value add content from current commodity based business model over a 4 year road map

- Mentor business unit GM’s to lead Lean Daily Management Systems and achieve breakthrough

improvements in KPI’s with significant lead time reduction

INGERSOLL RAND, Security Technologies, Carmel, IN 2005 – Oct 09

Sector Director, Lean Six Sigma & Operational Excellence – Americas & Asia-Pacific

Recruited to establish a united LSS organization and multiregional teams in the Americas and Asia-Pacific.

Directs 29 LSS leaders in the Americas (11 plants) and Asia (2 plants). Teams include Master Black Belts and

Master Sensei teachers supporting operations and sector business functions (Lean NPD, Regional Channels,

Category Global Marketing, Regional Sales, Finance, Sourcing, SIOP, IT, HR, Strategic Planning).

Responsible for driving LSS policy through development and execution of the Operational Excellence roadmap.

Coaches operations and business leaders to design 3-year strategies around the Operational Excellence

roadmap.

Outperformed P&L and balance sheet savings goals by 180%. Reduce new product development cycle time by

50% from business case through launch using VSM, lean tools and benchmarking with University of Kentucky.

Established lean supply chain based on lean manufacturing execution system (Pacemaker) and Heijunka

scheduling solutions drawing from e-Kanban supply chain systems.

Monitored financial viability and lean process design in startup phase of $30M Mexico greenfield zinc plating plant.

Led execution of LSS strategy using quarterly workshops for functional leadership to build Pathway to Excellence

Vision Matrix initiatives and build LSS project pipeline linked to KPIs, VSM lead times and inventory reductions.

Developed/implemented Value Stream Management workshops for transactional and manufacturing functions.

Deployed 143 VSM-based flow Kaizens with a cadence structure in conjunction with Shingijutsu.

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Manages professional development; mentored 3 Master Black Belts, 34 Black Belts and 163 Green Belts.

CASE NEW HOLLAND / NEW HOLLAND 1995 – 2005

Manufacturing Engineering Services Manager / LSS Deployment Leader, Wichita, KS, 03- 05

Led engineering services organization of 3 senior managers and 22 manufacturing/industrial engineers.

Served as LSS Deployment Champion and mentor for all senior Black Belts.

Instituted Kaizen and lean techniques, reducing waste 30% across assembly and robotic weld processes

Develop line balancing models to sustain flow manufacturing and pull systems in a high-mix-model environment.

Managed facilities engineering projects to support one-piece flow; reduced off-site warehouse costs by $1M.

Led Global Product Development-based product launches for 15 models within 3 platforms using APQP tools

(including DOE and PFMEA); cut launch ramp-up time from 6 to 2 weeks.

Mobilized Productivity Improvement Task Force, achieving an 8% efficiency improvement in 4 months.

Reduced machine downtime. Drove product cost controls through design engineering and labor standards.

Developed system simulation models with state university to reduce buffer sizes and introduce Kanban controls.

CASE NEW HOLLAND / NEW HOLLAND 1995 – 2005

Quality & Product Behavior Manager / Six Sigma Deployment Leader, Wichita, KS, 00- 03

Responsible for quality and product behavior as well as Six Sigma deployment at two plants during critical product

transitions. As Six Sigma Deployment Champion, delivered $2M in annual productivity improvements.

Relocated Skid Steer assy and weld processes using AQP tools and DMAIC, reducing ramp-up time 60%.

Outsourced 500+ components to Mexico plant; utilized AQP and Six Sigma tools to retain knowledge base.

Established early-detection quality metrics and incoming acceptance criteria using DMAIC methodology to modify

MIL sampling plans for 400+ suppliers in U.S., Europe, China, India and Mexico.

Established customer quality audit and OKOL/RTY processes for relocated product lines.

Executed transition from ISO 9001:1994 to ISO 9001:2000 standard without additional resources.

Quality & Product Behavior Manager / Six Sigma Deployment Leader, Belleville, PA, 98- 01

Initiated and developed Six Sigma deployment structure with extensive change management tools.

Spearheaded ISO 9001 certification effort and sustained registration by focusing on customer-centric behaviors.

Reduced quality costs 25% by establishing QA systems and process controls.

Directed quality and product behavior team comprising 5 direct/12 indirect reports; drove continuous improvement

processes and field improvement programs/campaigns, reducing warranty claims 18%.

Led customer satisfaction initiative linking manufacturing/engineering strategies with measurable improvements.

Provided product engineering inputs on prioritized customer concerns, cutting warranty claims an additional 12%.

Established supplier development programs for over 15 major suppliers (U.S., Europe, China, India, Mexico),

decreasing manufacturing and customer downtime 33%.

Manufacturing Engineer / Team Building Process Specialist, Belleville, PA, 95- 98

Initiated and promoted team-building activities as a process specialist throughout the plant.

Implemented CAD/CAM systems for CNC machine tools, reducing programming time by 50%.

Project-managed utilization of $2.5M in machine tool assets for cellular manufacturing.

Established SPC strategy and a computer-integrated manufacturing system with workstation terminals.

Developed machining process capabilities and controls, cutting scrap 75%.

PUBLICATIONS, EDUCATION & AFFILIATIONS

Publications: Driving Change in Manufacturing Quality Systems by selecting best in class off - the - shelf (OTS) software

platform. Rajesh Solanki, O. P Yadav, Canan Bilen, Int. J. of Process Management and Benchmarking, Vol. 1, No. 2, 2006

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Improving the NPD Process by Applying Lean Principles: A Case Study, Bimal Nepal, O. P Yadav, Rajesh Solanki,

Engineering Management Journal, Vol. 23, No. 1, March 2011

M.S.E., Computer Integrated Mechanical Engineering Systems, Temple University

B.S. with Distinction, Mechanical Engineering, M.S. University

Senior Member, American Society for Quality and Six Sigma Forum

Member, iSixSigma and Lean Enterprise Institute

AWARDS

Ingersoll Rand, Security Technologies President’s Award for Operational Excellence, 2nd Quarter 2008

Ingersoll Rand Chairman’s Award Finalist for Operational Excellence, 2006

CERTIFICATIONS

Lean Six Sigma Leader, Ingersoll Rand University, 2008

Advanced Business Leadership Management, Ingersoll Rand University, 2007

Lean Enterprise Leader, University of Kentucky, 2006

Kaizen & 3P Facilitator, Shingijutsu - Boeing, 2003

Six Sigma Deployment Champion, American Society for Quality, 2000

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