Frank Yankello

**** *. ******* ***** ( PEORIA, IL 61615

Phone: 309-***-**** ( Email: ably40@r.postjobfree.com

Manufacturing Operations Management

Manufacturing operations executive with 15+ years of international

management experience and a consistent record of success in achieving

revenue, cost containment, productivity enhancement, and delivery goals.

Able to guide and lead highly skilled, cross-functional teams in the

development, launch, and scale-up of leading-edge products and processes.

A Six Sigma Black Belt, experienced in Lean and MRP system implementation.

Core Competencies:

( Project Planning & ( Quality Assurance Controls /

Scheduling Standards

( Budget Planning & ( Team Building, Mentoring & Leadership

Administration

( Regulatory Compliance ( Process Reengineering

Management

( New Systems Development ( New Product Introduction

( LEAN and Six Sigma ( Problem Solving & Cross-functional

Deployment Change Management

( Turnaround Operations ( Contract Manufacturing Interface /

Management

( Start-up Business / ( Grant Proposals

Operations

Professional Experience

Firefly Energy, Inc., Peoria, IL

Firefly Energy is a Start-up spun-off from material science discoveries at

Caterpillar's R&D labs. Firefly develops new generations of lead-acid

batteries based on Carbon Foam substrates that deliver the energy and power

performance of advanced battery chemistries while maintaining the low cost

and safety advantages of lead-acid battery chemistry.

Vice President of Manufacturing, Oct. 2007 - March 2010 (company

closed)

Overall responsibility for Manufacturing, Facilities, Supply Chain,

Quality, and EH&S for a Battery Technology Start-up. Setup

manufacturing operations for Firefly proprietary Microcell plate

technology.

. Managed over $3.5M in facilities upgrades and expansion of a

53,000 ft2 brown field site to house R&D, Applied Engineering,

Manufacturing, and Corporate Offices.

. Developed and vetted proof of concept equipment for key unit

operations.

. Purchased and installed $7M in custom high volume production

equipment with capacity of 8.5 Million negative plates per year.

. Drove the implementation of ISO9001 compliant standard processes

and procedures.

. Implemented the use of Statistical Process Control, and Lean

concept such as Kanban.

. Implemented visual factory processes and metrics.

. Key member evaluating and selecting an Enterprise Resource

Planning system (ERP). Plexus ERP SaaS solution selected.

. Champion of a $2 Million 2 year ManTech grant to continuously

improve Firefly's proprietary negative plate manufacturing

processes.

. Developed Key Supplier base for critical Raw Materials and

outsourced Battery Assembly.

. Co-Leader of a $261M Grant Proposal for the Recovery Act Electric

Drive Vehicle Battery and Component Manufacturing Initiative.

. Developed Manufacturing Strategy for Asia

Cooper Bussmann, Ellisville, MO

Cooper Bussmann is a $550 million division of Cooper Industries, Inc.

Cooper Bussmann manufactures a wide variety of overcurrent and surge

protection products for the electrical, electronics, and transportation

industries, including power fuses, blocks & holders, disconnects, wire

connection products, magnetics, and breakers.

North America Director of Operations, June 2006 - Sept. 2007

Overall responsibility for 3 plants with more than 2,400 operations

personnel in the US and Mexico. Responsible for plant budgeting, and

strategy and execution programs for roughly 40% of the business. Also

responsible for the division engineering and manufacturing services

groups.

. Developed and implemented an action plan and countermeasure

approach to address management, engineering, materials

requirement planning (MRP), and equipment maintenance issues,

increasing the output of an under-performing Mexico facility by

30%. Reduced past due orders by more than $4 million, from a 3

year high to a 3 year low, in less than 6 months.

. Improved productivity by 4% annually through the use of Lean and

Six Sigma programs. Saved more than $500 thousand per year in

one US facility alone, utilizing Kaizens.

. Conducted weekly Kaizen events in the Juarez facility, typically

reducing labor by 40-60%, and improving cell output by 30-40%.

. Drove the implementation of world-class MRP and quality systems

by converting plants from a legacy system to SAP, and gained

TS16949 registration for the Juarez site.

. Ensured rigorous cross-functional management reviews of capital

expenditures by running quarterly meetings and supplying monthly

reporting for the $15 million deployed annually.

. Addressed weaknesses in the mergers and acquisitions (M&A)

process by developing standardized procedures for the due

diligence and integration phases, ensuring synergy realization.

Also conducted due diligence on target businesses.

. Addressed problematic new product and process launches by

implementing standardized procedures for defining project scopes,

supplier selections, equipment purchases, buy-offs, and

implementation into production.

. Reduced the personnel turnover rate of the Juarez facility by 50%

and obtained a 90% Christmas holiday return rate by instituting

key incentive and "out-of-the-box" benefits programs.

. Participated actively in a cross-functional business team that

drove strategic management of products for the commercial and

industrial markets. Prioritized and drove new product road maps,

product rationalization, product placement, and key cost-out

opportunities.

. Lead a complex transactional Lean project targeting problematic

product stock rotation and returns programs. Employed a cross-

functional approach, mapping the current process, and defining

policies and procedures for the customer base.

. Lead a transactional Lean project that is removing non-value

added activities from the Engineering Change Request /

Notification (ECR/ECN) System. This project reduced change

management cycle times by more than 70%, simple changes from 4

days to 1 day, and more complex changes from 30+ days to 7 days.

Tyco Electronics - Raychem, Menlo Park, CA, 1988 - 2006

Tyco Electronics is a $12.8 billion global provider of engineered

electronic components and industrial products for the automotive,

appliance, aerospace and defense, telecommunications, computer, and

consumer electronics industries.

Circuit Protection Division

The Circuit Protection Division is a $350 million business unit which

develops, manufactures, and markets a complete line of resettable current

limiting devices, fuses, surge protectors, varistors, electro-static

discharge protection devices, and micro-assemblies for the telecom,

automotive, and consumer electronics industries.

Operations Manager, 2004 - 2006

Overall responsibility for 2 plants, with more than 250 operations

personnel, and a major subcontractor in Asia. Responsible for planning

and plant level P&L reporting. Drove plant metrics in quality,

costing, delivery, and safety, meeting corporate goals and objectives.

Achieved year-over-year cost savings -over $5 million in 2005 alone.

. Set and drove goals and objectives for a key out-source supplier

in Taiwan, saving an average of 8% for 3 consecutive years. This

was accomplished by looking beyond a common purchasing cost down

approach, and instead, placing Tyco engineering and planning

staff on site to drive Lean and equipment / process related

engineering activities.

. Drove costs down by 20%-30% in key product groups by implementing

production improvement projects and moving products to low cost

manufacturing sites in China.

. Generated savings a of $276 thousand in FY04, and over $450

thousand in FY05 by managing a team of 17 Green Belts and 7 Black

Belts during our first 2 years of Six Sigma implementation.

. Led in the implementation phase of a $6 million acquisition.

This resulted in savings of $400 thousand annually.

. Ensured world class quality and health and safety systems by

maintained or gaining IS09001, QS9000, ISO14001, and TS16949

registrations. Under my watch, we received the fewest audit

action requests of the previous 3 operations managers.

. Actively participated in a cross-functional business team that

was responsible for tactical and strategic management of our $35

million telecom products business. This team prioritized and

drove new product road maps, product moves, strategic supplier

alliances, product placement, and private labeling agreements.

Manufacturing Engineering Manager, 2000 - 2004

Engineering Manager for new product introduction. Responsible for a

team of engineers who scaled products from development, and transferred

them to manufacturing sites worldwide.

. Drove in the introduction of a new product platform, and several

new product extensions for the telecom market. These projects

reduced the product size by 20%-40% and reduced our manufacturing

costs by 25%-50%. This endeavor entailed building prototype

equipment, specifying and managing capital projects for full

scale production volume automated assembly equipment, conducting

production scale-up in start-up production cells, and eventually

transferring the technology to low cost labor sites in Taiwan,

China, and Mexico.

. Improved key product yields to above 90% by redesigning the

factory layout, modernizing production equipment, and developing

and implementing several trade secret process steps.

. Participated actively in a cross-functional business team that

managed tactical and strategic products for the telecom market.

The team prioritized and drove new product road maps, product

moves, strategic supplier alliances, product placement, and

private labeling agreements.

. Championed a key operations quality effort by leading quarterly

worldwide engineering reviews to address trend quality data, and

implemented action plans.

. Teamed to develop a novel terminal design that enabled

significant size reduction of an overcurrent surface mount

device. Granted United States patent - US7148785 Circuit

Protection Device.

Thermofit Division

Thermofit is a $400 million business unit which manufactures a complete

line of Polymer heat shrink tubing, soldering devices, harness sealing

devices, heat shrinkable termination caps, and wire identification

products for the automotive, aerospace, and consumer electronics

industries.

Senior Development Engineer, 1997 - 2000

Senior Engineer in the Materials and Process Development group. Team

Leader in the development and production scale-up of new products, inks

and printing technologies for the wire and harnessing identification

marker business. Products primarily serviced the harsh environments of

the Defense, Aerospace, and Rail markets.

. Led in the introduction of numerous new products for the Wire and

Harness Identification Products group. Drove projects through a

4-stage development process, taking them from inception to

production implementation. These new products serviced the rail

and aerospace markets and increased sales by roughly $6 million

within 3 years.

. Participated actively in a cross-functional business team that

was responsible for tactical and strategic management of the $35

million Wire and Harness Identification Products business. This

team prioritized and drove new product road maps, product moves,

product placement, and private labeling agreements, increasing

sales by more than 20% for 4 years in a row.

. As a member of the division's Quality Improvement Team, addressed

several key reoccurring product design and manufacturing issues,

saving the company more than $100 thousand.

. Developed and implemented a new process that eliminated the use

of 5,000 lb. of organic solvent annually, resulting in $500

thousand in annual material savings.

. Teamed in developing the first commercially available continuous

length polymeric wire marker system. Granted United States

patent - US5766705 Marker Sleeve Assembly.

Process Engineer, 1994 - 1997

Manufacturing and Process Engineer for the specialty heat shrink tubing

business. Sole engineer responsible for 2 product lines with $20

million in annual sales, overseeing engineering change controls of

manufacturing specifications, MRP BOMS and routes, product quality,

productivity, on-time delivery, and profitability.

. Supported 30% annual product sales growth by developing and

implementing 4 high-speed integrated assembly processes, a $2.7

million capital project.

. Improved productivity by 15% and yields by more than 20% by

implementing key process improvements, saving more than $500

thousand annually.

. Ensured improvement and adherence to work and quality standards

by conducting internal audits of ISO 9000 /QS9000 quality

systems.

. Drove process improvement and standardization by implementing and

formally training operations personnel regarding statistical

process control.

Production Supervisor / Team Facilitator, 1988 - 1994

Facilitated 40 manufacturing operations personnel over 3 shifts, in the

Special Products tubing factory. Responsible for all aspects of first

line supervision and coaching of multicultural, multi-language

operations personnel.

. Teamed to introduce the divisions first self-managed work team.

Mentored operations personnel, and established systems to support

the work design. Developed and implemented visual standards,

cellular layout, a small highly cross-trained work force, and a

visual display of work area metrics to drive accountability and

problem solving.

. Analyzed product routings, and established the division's first

product group flow cells.

. Drove new manufacturing techniques, methodologies, and tools. As

Operations Team Champion, worked with engineering personnel in

the introduction and employment of Statistical Process Control

and Just-In-Time concepts, ultimately lowering production costs

by 50% within 3 years.

Stonhard Incorporated, Maple Shade, NJ

Stonhard is $30 million privately held corporation. They are the leader

in the manufacture and installation of high performance polymer floor,

wall, and lining systems for the industrial and commercial industries.

Senior Field Engineer, 1986 - 1988

Provided technical support to two divisional headquarters covering

states west of the Mississippi. This involved extensive domestic and

limited international travel.

. Supported 25-30% year-on-year sales growth in the Western region

by providing inside and on-site technical sales support, project

management, training and evaluation of field engineers and

installation crews, contract reviews, and office management

responsibilities.

. Supported the introduction of new products by conducting field

evaluations, developing new installation techniques and

procedures, and establishing quality control procedures.

. Led the team in 2 critical installations in Costa Rica and

Bolivia, and for key international customers.

Education

B.S. Degree in Chemical Engineering,

Pennsylvania State University. May, 1986.

ADDITIONAL SKILLS:

. Post graduate courses and seminars at Stanford University in Operations

Research and Supply Chain Management

. Lean Six Sigma "Black Belt" training (160 hours)

. (GDP) Goal Deployment Process

. Courses in TS16949 Quality Systems Auditing

. Courses in ISO9000/QS9000 Documentation Preparation

. Courses in ISO9000/QS9000 Quality Systems Auditing

. Courses by Eastern Michigan University in Statistical Process Control

. Certified in E-chip and MiniTab for Statistical Design of Experiments.

. Completed various courses in Lean, SPC, polymer processing, design tools,

and supervisory skills.

. Well versed in the PC Windows and Apple Computers.

. Well versed in Microsoft Excel, Word, Power Point, Works, Project and

other engineering software tools.

. Broad experience in electronic and electrical components manufacturing.

Industrial experience with High Speed Automated Pick and Place Assembly,

Detailed Hand and Semi-automated Assembly Processes, Solder Reflow, CNC

and High Speed Punching and forming of components, printing (laser, ink

jet, pad printing, thermal transfer, engraving, screen printing), PCB

Fabrication Processes (etching, plating, drilling, lamination, photo-

resist application, exposing and developing, Screen printing), Automated

Electrical Testing, High Energy Electron Beaming, Polymer Compounding,

processing of Thermoset Polymers, and Thermoplastic Polymer Extrusion,

Molding, Lamination, and Battery component and assembly processes.

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