Six Sigma Design

ALI FOUANI

**** ******** ****, ******* *****, IL 60089

E-MAIL: abjwpa@r.postjobfree.com; CELL: 313-***-****

Private & Confidential

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• Seeking a leadership position in a competitive and innovative organization that provides responsibility and professional growth.

• Interviewed by Genna Weiss from Six Sigma IQ (Podcast: DFSS tools you need to know right now).

http://www.sixsigmaiq.com/podcenter.cfm?externalID=316

Professional December 2007 – Present Baxter Healthcare Round Lake/IL

Experience Technical Director/ Design for Six Sigma Master Black Belt

• Fostered positive, productive relationships with internal customers within business unit.

• Acting as an internal consultant/reviewer to multiple business units, including Engineering Management, Risk

Analysis, Design Control, and Manufacturing issues.

• Developed multiple transfer functions (Volumetric Pumps/Disposable Pumps) that are instrumental in

understanding the product design.

• Planned and developed multiple MSA’s and DOEs in multiple product/process design.

• Worked with consultants to revamp some procedures within Design Control.

• Planned & executed multiple sessions in QFD, Pugh concept selection, DFMEA, PFMEA, Brainstorming,

Strategic initiatives, making practical sense from challenging data analysis, and multi-objective optimization

analysis.

• Critiqued and recommended revisions to Risk Management Procedures and Templates.

• Partnered with Manufacturing to improve internal competencies when using PFMEA.

• Designed a screening DOE (Placket Burman) with resolution III that improved quality (The big Y = Silver

Coating), reduced scrap, resulting in a $170K savings per year.

• Designed and analyzed a DOE for disposal pumps with 4 outputs. Extracted transfer functions, recommended

proposed settings for inputs, & simulated model via Monte Carlo.

• Received an Award of Recognition at the 35th Annual NSBE; National Convention (Speaking/open Forum

Discussion). Executive Round Table discussion about leveraging Engineering and Innovation.

• Coached and mentored material team on non PVC tubing development effort by utilizing DFSS tools.

• Developed Design for Six Sigma Overview Training with collaboration with Business Excellence.

• Created company’s DFSS training material (QFD, Pugh Analysis, TRIZ, MSA, Regression, DOE, DFMEA, and

PFMEA, and Control Plans).

• Partnered with team leaders to provide coaching and guidance, and recommended DFSS tool usage.

• Recommended corrective actions to internal system processes that are lagging.

• Analyzed multiple sets of data, and recommended corrective actions.

• Recommended process parameters for injection site packaging thus improving the seal strength of the package.

September 2001 – December 2007 Lear Corporation Southfield/MI

Design for Six Sigma Master Black Belt

•Participated in the executive steering committee for Lear’s Seating Division.

•Key team player in launch support supporting internal and external customers. Met all implementation

deadlines and benchmarks.

•Developed multiple DOE strategies in product development & to solve manufacturing variations. Extracted

multiple transfer functions & used simulation (Crystal Ball) to further improve design/process.

•Created Quality Control procedures and set benchmarks for quality goals achievement.

•Masterminded FMEA audits that significantly improved product and improved depth of knowledge and

expertise among employees.

•Integrated FEA & DOE & proved that the combined concepts can result in quality products. This results in

reduced time in product development (Outputs modeled “Frequency –BSR”).

•Developed a plan that includes DOE’s & RED-X techniques to solve for component/build variation with Tier

II supplier for one of their systems. Presented findings to supplier, & recommended corrective actions.

•Integrated Six Sigma, DFSS, and Red X in several studies.

•Recommended studies and experimentation to improve headrest effort & rattle.

•Developed multiple DFSS courses, conducted DFSS training of more than 1100 Engineers.

•Visited multiple Lear plants and suppliers for quality concerns, recommended strategies and action plans to

solve concerns.

•Reviewed Black Belts projects from multiple plants, suppliers, and Europe. Recommended corrective action

and revisions.

•Traveled to Tier II supplier in Mexico to help with quality concerns. Established quality measurements,

suggested more than 30 ideas/concerns that resulted in improved product/process, improved throughput &

productivity; Designed several POKA-YOKE fixtures; Redesigned GMX-295 End Frame line, which resulted

in increased outputs of parts from 245/day to 320/day, in addition quality improved. Several data analysis, a

DOE; applied Lean Tools/philosophy, DFSS, and manufacturing expertise. The above allowed the supplier to

ship good parts & prevent closure/s to our plants and the customer. Resulted in savings of $300K.

•Trained, coached, and mentored by Shin Taguchi in two critical projects for General Motors. Published paper

with GM as a result; Title: Understanding customer’s feedback with respect to Backset (FMVSS 202a) and

head-restraint comfort.

•Coached engineers in the use of Concept FMEA to aid in developing safety systems. Responsible in

reviewing and auditing multiple programs in the usage of FMEA.

•Developed Design for Lean (Design for Manufacturing and Assembly) module to be taught as a DFSS

module.

•Recommended revisions, and critiqued DFSS consultant materials.

•Trained directors, managers & engineers in Design for Six Sigma methodologies. Classes taught:

Introduction to DFSS, QFD, VOC, TRIZ & Design Trade-offs, Basic Statistics, Reliability, Design for Lean,

DFMEA, Regression & DOE, Product Design and Variation, and Design Optimization.

•Mentored DFSS teams through their initial start-up of DFSS implementation.

January 1998 – August 2001 Black Belt (DMAIC)

•Worked on first assigned six-sigma project, dealing with General Motors Service operations. Constructed a

customer survey, received customer feedback, analyzed feedback, and reported to management corrective

actions.

•Initiated a Bill of Material project at GM division; project got expanded to include all other divisions within

Lear. Project was handed off to Customer Focus Division.

•Worked with the maintenance dept. at Lear Auburn Hills plant to reduce maintenance inventory, control of

material, and standardize process. Estimated yearly saving of recommended actions $450K.

•Analyzed, improved, and controlled indirect material (gloves, knives, small tool, etc.). Estimated yearly

savings are $36K.

November 97 – February 2000 (From 1997-1998 Delphi Automotive; Seating division got acquired by Lear)

Sr. Product Engineer

• Project coordination of seat components and assemblies including liaison with customers and suppliers to coordinate timing,

assure quality standards and the completion of engineering work orders.

• Coordinated with designers and manufacturing engineers to assure tooling and processes per program requirements.

• Implemented on cost saving issues and continuous product improvement that resulted in saving of $300K.

• Root caused rattle and noise condition in Fiat Multipla and H-Car programs; recommended corrective action and solutions.

• Redesigned front stops (major design adjuster changes “safety concern”) for the Fiat Multipla program, reduced travel per

customer design.

• Traveled to Lear Italy to help on the start up of the launch for the Fiat Multipla. Transferred all design responsibilities from

Lear USA to Lear Nottingham.

• Helped industrial engineering with several MOST studies for new products.

February 95 – November 97 Friendship Industries Inc. Sterling Heights/MI

Project Engineer

• Engineering duties included design conception, documentation and implementation as specified by customer.

• Investigated customer complaints and recommended corrective action.

• Achievements include introducing several new fixtures and assembly equipment into the Fuel Filter technology line.

• Introduced a water leak tester for detecting any leaks that might occur from a sunroof coming out of production line. Worked on

leak testers related to fuel filters.

• Designed a vibrating fixture to align lamination stacks used in small motors for automotive applications.

• Travelled to Mexico to understand the requirements needed for an assembly line. Designed and managed the assembly line till

transfer to the customer.

August 94 – February 95 Gonzalez Design Engineering Warren/MI

Specifications/Product Validation Engineer

• Prepared military specifications and standards for the US Army Tank-automotive and Armaments Command in accordance with

requirements.

• Converted military documents into commercial item descriptions.

• Performed engineering studies for other Department of Defense Standards for applications in military specifications.

Education: Lawrence Technological University

Masters of Engineering in Manufacturing Systems; 2003

Completed Course work related to a Doctorate Program in Manufacturing Systems

University of Michigan - Dearborn

Bachelor of Science in Mechanical Engineering; 1994

Professional Accomplishments/Training:

1999: Successfully completed the following components of Lear Internal Training Program/University of Michigan (3.6

CEU’s Awarded): Human Factors and Ergonomics, Materials and Recycling, Vehicle Electronics Occupant Safety,

Noise Vibration and Harshness / Acoustics, Vehicle Packaging, Automotive Interior Systems.

• Dec 2000: Successful completions of one-week course “Mynard Operation System Techniques”.

“Certificate Awarded” for BasicMOST Applicator.

• September 2001: Design for Six Sigma Training by Statistical Design Institute.

• September 2001 – Present: Technical and Leadership Advisor to Product Lifecycle Management Tech Group (Society of

Manufacturing Engineers)

• September 2002: Train the Trainer by Crystal Clear Concepts

• January 2003: Leadership Training by Crystal Clear Concepts.

• May 2003: Design for Six Sigma Master Black Belt Certification thru Lear Corporation.

• July 2003: Red X (Shainin Techniques) at General Motors University.

• June 2005: Managing a Diversity Workforce Training by Cornell University

• December 2005/January 2006: Attended Design for Six Sigma Training at General Motors Corporation

(3 Weeks). Training was done by ASI (Shin Taguchi)

• January 2007: Attended Design for Six Sigma Training at Chrysler (one week) by Shin Taguchi.

• April 2007: Lean Training (Lear Corporation)

• May 2007: DRBFM (Design Review based on Failure Mode) training at Toyota Motor Company

• February 2008: PDP Training; Baxter Training

• August 2008: Design for Reliability; Baxter Training

• September 2008: Software Test & Performance Conference; Boston MA

• December 2008: Compliance Boot Camp; FDA News/Edu Quest; Scottsdale AZ

• December 2008: Software Reliability & Integrity by Steven Arndt

• March 2010: Certified in Configuration Management “CMII”; Institute of Configuration Management; Phoenix AZ

• May 2010: Response Surface Methodology using EcHip; Baxter Training.

Specialties: Include: VOC, VOP, QFD, Pugh Concept Selection, Product Development and Launch, Design for Manufacturing &

Assembly, Systems Thinking, Lean Design, Six Sigma, Design for Six Sigma, Engineering Management, Product and

Process Improvements, Risk Management, and Problem Solving.

Professional The Alumni Association of the University of Michigan-Dearborn;

Memberships: The Society of Manufacturing Engineers

Professional Strong motivation to pursue higher education and academic achievements to meet the increasing demand

Interests for additional skills and professionalism in the job market.

Contact this candidate