Manager Six Sigma
Resume:
James E. Wilgus
**** *********** ***** abk4gu@r.postjobfree.com
Alliance, Ohio 44601 wilgusj@americanstandard
.com
Engineering Manager/Operations Manager
A highly competent Engineering/Operations Leader who provides refined
managerial and analytical skills by drawing on 20 years of
manufacturing experience. A value adder to the organization by
employing continuous improvement tools such as Lean, Six Sigma, and
quality system elements. Delivery of bottom line results by combining
problem solving, technical, and interpersonal skills to drive cross-
functional process improvement teams. Successfully manages capital
projects from concept through startup and de-bug.
CORE COMPETENCIES
. Chemistry and processes for Metals, Glass, Acrylics, Polyurethanes,
and Polyesters
. Certified Six Sigma Black Belt
. Lean Principles for 5S, Value Stream Mapping, Total Productive
Maintenance, SMED, Work Study, Visual Factory, and Kaizen
. Project Management
. Six Sigma based quality and process control systems including PPAP,
FMEA, 8D, Control Plans, Measurement & Analysis System, Change Control
. Employee Training and Professional Development
. Environmental, Health and Safety
EXPERIENCE
A. S. America Inc., Salem, OH
2008 - Present
Metals Operations Manager/Engineering Manager
Oversight and responsibility for 5 - 10 supervisory and 120 - 200
operations personnel in a multi-shift, union environment. Deploy resources
as needed to meet production requirements and maximize productivity. Drive
schedule attainment, safety objectives, and internal process performance
metrics. Train, cross-train, mentor, and coach salaried personnel. Create
PMPs, PDPs, and assess employee performance against stated business
objectives.
. Exceeded all safety and process performance objectives during a
declining business cycle
. Improved internal quality compliance year over year for the last 2
years
. Development and production ramp up of modified product design
resulting in $1 million cost savings
. Implementation of modified coating system for enhanced product in-
service reliability
2004 - Present
Engineering Manager, Metals & Acrylics
Direct a team of five leadership employees and 14 technicians for
operations, engineering, quality control, and process control within a
major company business unit. Developed and implemented ISO based quality
and process control system in conjunction with the Six Sigma methodology
for FMEA, DMAIC, and Process Change Control. Led development and
implementation of lean enterprising with the integration of value stream
mapping, employee Kaizens, and capital expenditure. Manage plant quality
system. Interact with field service personnel to resolve product quality
concerns. Responsible for Six Sigma training and certification programs.
. Improved productivity over three years of 60%+ across three major
manufacturing processes.
. Improved on time fill rates from 85% to 98%.
. Increased productivity of steel bathtub product line by 20%.
. Managed manufacturing design and ramp for timely launch of two new
Acrylic product lines.
2002 - 2004
Metals Engineering Manager
Managed two salary and 9 indirect hourly technicians. Built material
science knowledge base for chemical process. Developed and installed
quality system elements for molding process.
. Reduced process scrap 50% saving over $500 K/yr.
. Used six sigma tool box to qualify and validate materials savings of
20% through both usage reduction and alternative supply sourcing.
. Increased the production rate of bathtub product line by 10% through
mold cycle time improvements resulting savings of $400 K/yr.
2000 - 2002
Six Sigma Methods & Process Engineer
Troubleshooting and process improvement responsibility for manufacturing
facility. Successful completion of Six Sigma Black Belt training
program. Achieved Six Sigma Black Belt status by recording $1 Million of
savings through material usage reduction, external quality improvements,
and machine productivity.
. Directed and assisted black belt and green belt candidates in three
other American Standard business units in Canada and Mexico.
. Built a foundation for lean enterprising based on work study,
process/work method documentation, training programs, and defined
accountability.
. Root cause determination of PVC pipe joint leaks.
BWX Technologies, Inc., Barberton, OH
1998 - 2000
Environmental Control Specialist
Managed environmental compliance activities for the facility.
Responsible for obtaining all air and water permits, analytical work,
solid and hazardous waste disposal, and reporting. Administered
environmental and safety training to hourly employees.
. Reduced budget by 30% over 2 years by implementing Hazardous Waste
cost reduction and volume reduction measures.
. Relocated and remediated a Hazardous Waste 90-day accumulation area.
American Standard, Inc., Salem, OH
1992 - 1998
Chemical Engineer
Managed environmental compliance activities for the facility.
Responsible for obtaining all air and water permits, analytical work,
solid and hazardous waste disposal, and reporting. Administered
environmental and safety training to hourly employees. Also tasked with
process improvement activities and responsible for the successful
completion of several capital projects.
. Specified, purchased, and installed air pollution control equipment
for styrene mitigation.
. Led a Demand Flow Manufacturing project to improve flow in acrylic
assembly operation.
. Identified and abated source of airborne contamination causing defects
in a coating process.
. Installed an enamel recycling program.
Chi-Vit Corporation, Urbana, OH
1987 - 1992
Sales and Service Engineer
. Analyzed and solved coating problems in customer facilities.
. Formulated coatings for new applications.
. Scaled up bench formulations to production.
EDUCATION
1987 Ohio University Bachelor of Science Chemical
Engineering
2003 American Standard Certificate of Six Sigma Black Belt
Completion
2006 University of Tennessee Lean Fundamentals Certificate of
Completion
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