Phillip A Kalsch

**** ****** **** ***** 972-***-****

Carrollton Texas, 75007 ablp7f@r.postjobfree.com

SUMMARY

Results oriented and data driven manufacturing professional with extensive

background in diverse products and processes. Reputation for developing

and mentoring teams which exceed expectations. Career encompasses new

product and process introductions, system implementations and continuous

improvement efforts. Career reflects personal integrity, adaptability,

focus, analytical and problem solving skills. Require challenging work and

quality environment.

ISO/TL 9000/Six Sigma New Product and Process Statistical Process

Project Management Introductions Control

SAP Root Cause Analysis Lean Manufacturing

Budgeting Mentor/Coach

PROFESSIONAL EXPERIENCE

Corning Cable Systems, Keller, Texas 1994 - 2009

Quality Manager 2005 - 2009

Served as Quality Manager improving plants performance related to customer

defects, established plant Six Sigma Black Belt and Green Belt subject

matter experts, improved plant quality metrics, and minimized department

expenses. Duties included but not limited to ISO and TL / 9000

registration, certification and metrics reporting, management of continual

improvement portfolio, coordination of calibration, metrology, and supplier

performance functions.

.

. Volunteered to serve as SAP Site Implementation Lead for the Keller Plant

while continuing duties and responsibilities as the Quality Manager from

2006 through 2008. Successfully completed three ISO/TL 9000 audits and

participated in Corning's Manufacturing Excellence Pilot Audit achieving

exemplary results.

. Directed support team of six AS/400 experts in data conversion needed for

SAP implementation. The team analyzed and converted over 5000 bills of

materials and over 250,000 data elements needed to exchange legacy system

data into new SAP process. Data successfully corrected with plant having

fewest number of data related issues during the SAP conversion.

. Coordinated and scheduled SAP training for Keller facility prior to

system implementation. Over 350 SAP end users were trained in four

different modules encompassing Finance and Controlling, Plan to Produce,

Shipping, Receiving and Warehousing functions. Served as SAP Security

Administrator prior to implementation working with managers and

supervisors assigning access to end users.

. Recognized for leading efforts winning the 2005 Corning Cable Systems

Quality Cup Award for Most Improved Plant. Improvements achieved were a

35% reduction in customer complaints and a 67% reduction in customer

feedback response time. Coached and mentored department engineers and

supervisors on proper evaluation and preventive actions.

. Received a Corning Cable Systems Excellence in Action Award for Plant

Gross Margin Improvements in 2006. Established a core of 15 Green Belts

and 10 Black Belts in 2005 used to support continuous improvement

projects that contributed over four million dollars in cost savings in

2006.

Production Manager 2003 - 2005

Managed and directed daily production requirements of six production

departments consisting of 200 operators. Utilized flexible work force to

meet constantly changing demands for fiber to the home product lines needed

to support Verizon's goal for one million homes passed. Utilized

performance metrics and worked with department supervisors to identify

opportunities to improve quality, on time performance and direct labor

costs of products.

. Revised and modified plant restructuring plan by retaining 20 key

operators needed to help support fiber to the home product launch for

Verizon. Operators provided the backbone of flexible work force needed

to meet the changing order demands placed by customer. Plant was able to

meet on time delivery performance of 99.3% for over 25,000 line items

shipped.

. Incorporated the use of temporary labor to help augment flexible work

force, reducing the labor content of product lines by 33%.

. Lead and supported Plant Safety Committee and helping revise and update

Plant Safety Programs and documentation. Provided subject matter

expertise in the areas of laser safety, compressed gases and robotics and

automation.

Manufacturing Engineering Supervisor 1999 - 2003

Directed, coached and mentored a staff of manufacturing engineers and

technicians for new product and process introductions. Identified and

prioritized opportunities for continual improvement in existing products

and processes by using department metrics. Worked closely Supervisors,

Department Leads and Operators to improve product quality and on time

performance measures.

. Utilized Six Sigma methodologies to increase LC fiber optic connector

capacity and yield. Efforts resulted in a 400% increase in the delivery

of fiber optic connectors needed to support the fiber optic cable

assembly businesses.

. Established initial product line for Optical Manufacture Services

Department at the Keller Plant. Hired and integrated new engineers and

technicians needed to support product line and production staff. First

product line was operational within 60 days after decision was made to go

live.

. Led engineering efforts to reduce the cost of Variable Optical Attenuator

product line. A total of $428,000 savings was implemented with another

three million dollars identified.

. Cost reduction plan also reduced scrap costs of product by 80%.

. Selected as part of plant Manufacturing Engineering staff to coach and

mentor Lean Manufacturing Principles to production departments. Efforts

resulted in excess of 1 million dollars in cost savings.

. Served as key contributor in establishing plant as one of the first

Manufacturing facilities to achieve ISO/TL 9000 compliance.

EDUCATION

Master of Science, Industrial Engineering

University of Texas at Arlington

Bachelor of Science, Metallurgical Engineering

University of Illinois at Chicago

PROFESSIONAL DEVELOPMENT

SAP, Six Sigma, SPC, Corning Basics of Manufacturing, Lean Manufacturing

Kepner-Tregoe Problem Solving and Decision Making Techniques

.

1985 through 1996

Held Top Secret Security Clearance while serving on as an officer with the

US Army

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