Six Sigma Engineer

SHANNON K. DILLS

**** ***** ****** **** *****, CA 90808 562-***-**** (home)

562-***-**** (cell) 562-***-**** (work)

Summary of Qualifications:

o 19 years experience in Lean and Human Factors/Ergonomics. Expert Lean

leader and team builder.

o Led 45 Lean events such as: Value Stream Mapping, Accelerated Improvement

Workshops (Kaizen), 5S, Six Sigma, Root Cause/Corrective Action.

Achieved $5M+ cost savings and $6.5M cost avoidance.

o Experience deploying Lean and ergonomic programs in production and office

areas. Hold numerous Lean certifications to lead, and train others to

lead, Lean events.

Professional Experience:

The Boeing Company: 1996 to present

Lean Practitioner/Quality Specialist - C130 Avionics Modernization Program

o Strategically identify, lead Lean events to achieve cost benefit.

o Completed 13 Lean projects with $4M cost savings and over $1M cost

avoidance.

o Led projects in areas for first-time Lean application, including external

suppliers.

o Representative to Long Beach Site Six Sigma Steering Team. Review Green

Belt projects, mentor Green Belt candidates, teach Six Sigma classes.

o Black Belt Project in work: recover profit loss of $600K.

o Employee Involvement (EI) Steering Team leader for C-130 AMP and B-1

programs (70 teams). Led 31 EI teams to achieve $5M cost avoidance in

team-based improvements. Trained 100+ managers in EI.

Lean Practitioner - C-17 GSP

o First employee to deploy Lean in Long Beach in office environment;

strategize and facilitate Lean events for Long Beach office and remote

Air Force Base teams

o Six Sigma Green Belt project saved $1M, prevented contract from being

cancelled, and enabled future contract wins. Achieved $.4M cost

avoidance in Value Stream Mapping events.

o Cleared funding roadblocks between Boeing and government to accelerate

Lean events.

o Taught Lean Office classes; recruited by other Long Beach programs to

conduct office events.

o Initiated ergonomic program for entire C-17 GSP Program.

Lean Practitioner - Accelerated Improvement Workshop (AIW)/Kaizen Leader -

717 Production

o Led 10 AIW's/Kaizen events to decrease cycle time across all production

processes.

o Achieved >50% cycle time reduction in all AIW's.

o Created Lean teaching material. Taught union, salary, management,

leadership on Lean implementation.

Ergonomist - C-17 Production Operations

o First ergonomist hired. Developed strategies to reduce ergonomic

injuries. First year: 47% reduction in ergonomic Lost Workday Case Rate;

24% reduction in ergonomic recordables.

o Trained 100+ employees across Boeing sites to conduct ergonomic

assessments.

o Trained 17 teams in 1 month on back-injury injury prevention methods.

Created and implemented stretching program; daily stretchers increased

from a 30 to over 200.

o Coordinated Industrial Ergonomic Technical Exchange, where 80 ergonomists

from 22 sites shared best practices, lessons learned, solutions.

o Conducted ergonomic testing on pneumatic hand tools to guide $2.8M hand

tool purchase.

Human Factors Engineer-B-1B Program

o Provided Human Factors and Ergonomic design guidance for B-1B aircraft

(displays, bomb loading and maintenance tasks) and Navy (two command and

control centers for future Destroyer ships).

o Designed layout for two Boeing command/control laboratories. This lab

enabled Boeing to win large Army contracts.

Human Factors Engineer- Commercial Aircraft Division

o Managed, executed, and obtained FAA certification for MD-90 Saudi Arabian

Program pilot mental workload study. Having only six months aerospace

experience, completed on time and within budget.

o Provided Human Factors analysis and recommendations for cockpit, cabin,

and maintenance user interface design issues. Assessed issues in

production, gave recommendations for engineering changes.

Delco Electronics/Hughes Research Labs - Human Factors/ Ergonomic Engineer

8/95 to 6/96

o Managed evaluation of automobile collision-avoidance system. Developed

and tested various alerting methods for effectiveness. Tested designs on

representative end-users in simulator and moving vehicle.

Systems Technology, Inc. - Human Factors/Ergonomic Technician 12/93

to 8/95

Conducted user evaluations in vehicle simulator to assess automobile

collision-avoidance systems and drowsy-driver monitoring devices.

Created experimental designs, ran subjects, wrote final reports.

Xerox Corporation - Human Factors/Ergonomic Specialist 6/91 to 12/93

Assessed usability of printer documentation and provided recommendations

for improvement.

EDUCATION/CERTIFICATIONS:

M.A. Human Factors/Ergonomics, CSU Northridge, 12/00. GPA 3.82

B.A. Psychology, CSU Northridge, 5/91. Cum Laude, GPA 3.71

Certified Accelerated Improvement Workshop (AIW) Leader: 1999

Certified Value Stream Mapping (VSM) Leader (2003) and Coach (2008)

Certified Advanced Root Cause Corrective Action (RCCA) tool Leader (2008)

Certified Six Sigma Black Belt - Villanova University (2008)

Certified Six Sigma Green Belt (2007). Black Belt (pending) - Boeing

Certified Boeing Trainer (Training Techniques)

Certified Employee Involvement Team Tools Trainer

ACHIEVEMENTS:

2010: Recognition/cash award from sub-division VP for exceeding Cost

Reduction Initiative goals

2009: Quality Coin for Lean Engagement C-130 AMP

2007: Quality Coin for Lean Contributions to C-17 GSP

2005 C-17 Team Safety Award Recipient: Wing Trailing Edge Team for

Ergonomic Improvements

2005 EHS Innovation Award Recipient: Chip-Free Factory

President - CSUN Psychology Association 1991

Venice High School Student Body President 1986-1987

Girl Scout Gold Awardee - 1986 (equivalent to Eagle Scout)

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