Engineer Six Sigma

**** ******** *****

Brunswick, Ohio *****-

****

* *****, ****

Dear Staffing Professional,

My name is Gene Smith, and I am a results-oriented manufacturing

change-agent who is actively seeking a new adventure in my career. My

training and experience have prepared me to strongly impact any

organization seeking to improve its cost, quality and customer service

position in competitive markets. I am experienced in manufacturing consumer

products, industrial products, and medical devices, with hands-on, career-

level experience in the following areas:

Manufacturing / Industrial / Process Engineering

. Product development / innovation

- Mercury / Metal Halide lamps

- HP Sodium lamps

- PVC window products

- X-ray anode targets

. Process development / innovation

- product assembly methods

- glass / quartz processing

- product assembly

- resistance welding

- thermal bonding

- mechanical fastening

- high vacuum cleaning

- soldering

- packaging

. Certified Six Sigma Blackbelt

. Greenbelt instructor / mentor

. Training curriculum design

. Equipment development / innovation

. Realtime uptime expedition

. Cost reduction projects

. Capital equipment justification

. Cost vs benefits analysis

. Ergonomics / human factors design

. Time study / analysis

. Minitab

. Pareto / Cause & Effect / Charting

. Statistical Process Control

. Gage Repeatability / Reproducibility

. Analysis of Variance

. Lean manufacturing instructor

. Kaizen event leader

. Value Stream Mapping

. Takt operation pulse

. Line balancing

. Heijunka / level loading

. 5S / visual management

. Standard Operations

. Quick changeover (SMED)

. Error-proofing

. Late point identification

. Single piece flow

. Kanban / JIT logistics

. Total Productive Maintenance

. Product rationalization

Design / Automation Engineering

. AutoCad, SolidWorks

. 10 robotic integrations

. Programming

- GE / Rockwell / TI PLC's

- Motoman / Adept robots

- GE / Xycom / Eaton HMI's

- Parker motion controls

- CIM software development

. High speed rotating equipment

. Bench / prototype processes

. Pneumatics / cams / servos

. Ethernet / RS232 / RS485

. Open loop stepper drives

. Closed loop servo drives

. Aggressive environments

. Conveying systems

. Packaging / palletizing systems

. New product introduction

. Design for manufacturability

. Process yield improvement

. Process speed increase

. Maintenance planning

. Inventions / Patent award

. Tactical thinking

Engineering Management

. Budget analysis / execution

. Demand / supply chain analysis

. Program management

. Strong customer advocacy

. Business acumen

. Kaizen Promotion Office

. Direct supervision: 6 engineers

. Indirect supervision: 21 hourly

. Cycle time reduction

. Warranty issues resolution

. Advanced MS Excel macros

. MS PowerPoint, Access, Outlook

. Visio, Visual Basic, Oracle

. Presentation skills

. Strategic thinking

Please hold all communications with me in confidence. I can be reached

through my voice mail at home: 330-***-****. I look forward to

personally discussing opportunities with you in the near future.

Sincerely,

Eugene A. Smith

Eugene A. Smith 330-***-**** home

2996 Benjamin Dr 330-***-**** cell

Brunswick, Ohio 44212

abmcix@r.postjobfree.com

Experience

GENERAL ELECTRIC COMPANY - HEALTHCARE - CLEVELAND, OHIO

GE Healthcare's Cleveland Target Plant is the leading manufacturer in

the world of X-ray Anode Targets, the key technical component in x-ray

tubes manufactured by GE, Siemens, Varian, Philips, and Toshiba.

2008 - 2009 Materials Manager

Manage $31MM raw material buy, lead kaizen efforts to drive

business cash flow and customer satisfaction by reducing

manufacturing cycle time and driving on-time delivery. Direct 3

hourly associates.

. Reduced raw material inventory from $14MM to $8MM, WIP from $4MM

to $2MM, and cycle time from 12 weeks to 6 weeks, using lean

manufacturing techniques. Employed visual management to sustain

reductions. Led lean training sessions and promoted kaizen

efforts throughout the plant.

GENERAL ELECTRIC COMPANY - LIGHTING BUSINESS - RAVENNA, OHIO

Ravenna Lamp Plant is GE's Global Center of Excellence for the

manufacture of high intensity discharge lamps, typically used in

industrial and commercial lighting applications, such as highway and

stadium lighting.

2006 - 2008 Manager, Manufacturing Engineering

Direct efforts of 5 salaried engineers and 1 hourly engineer.

Supervise Machine Shop Facilitator with 21 hourly tradesmen

reports. Manage $1.9MM manufacturing controllables and execute to

plan. Program manager for all on-site ($1.3MM) Total Cost Out

effort, Environmental Health and Safety, and facilities projects,

including identification, justification, and tracking.

. Developed and led integration of high speed packaging program,

eliminating $1.2MM direct cost and reduced production cycle time

by 40 hours (30%)

. Implemented TPM principles to drive uptime on lamp test

equipment from <60% to 95%, while cutting daily maintenance

requirements 95%. Reduced operator ergonomic stress while

driving productivity.

. Beat controllables budget by $70M (3.4%) and delivered $2.2MM

productivity in 2007

2002 - 2006 Lean Six Sigma Black Belt - Senior Process Engineer

Create a lean manufacturing culture in a fast paced, high volume

manufacturing operation. Shape the lean implementation on Lighting

business's model value stream, High Speed Finishing. Facilitate on-

site training and mentor salaried and hourly personnel in lean

strategies and techniques. Lead kaizen events on the manufacturing

floor, and empower production line process-owners to execute

continuous improvement. Drive key business metrics: reduced in-

process and finished goods inventory, minimize production cycle

time, maximize product availability (service), and optimize

production mix.

. Reduced finished goods inventory from $16.5MM to 10.5MM y/y and

RIP inventory from $8MM to 7MM y/y by reducing production line

changeover times, scheduling 90% of level-loaded volume each

week (heijunka), and developing supply chain flow to eliminate

production material outages.

. Pressed service levels (line filled/lines ordered) to all-time

high 98.0%, up 10.8pts over previous year. Reduced average cycle

time 17 days by implementing real-time schedule attainment

tracking.

. Kaizen events: Led 26, including 2 Shingijutzu-mentored events,

participated in 17, and mentored 5 in 4 different plants.

Developed and taught "Lean Set-up Kaizen Methods", "Error-

Proofing Techniques", and "Heijunka: Factory Loading". Led

Action WorkOuts focused on 5S, set-up reduction, value stream

mapping, total productive maintenance, jidoka, and just-in-time.

. Conceived, designed and implemented 4 robotic workstations,

reducing labor content by $455,000 annualized, increasing line

speed by 30%, and eliminating a key product liability defect.

Defectives were reduced from 5.5% to 2.1% (2.4pts above goal)

and increased uptime from 65.5% to 81.3% (9.8pts above goal).

. Deployed the Six Sigma tools to eliminate a key ergonomic safety

issue. Trained plant VPP Ergonomics Team to use DMAIC techniques

such as process maps, FMEA, C&E Matrices, and fishbone diagrams

to diagnosis and solve problems.

Eugene

A. Smith

1 of 2

1994 - 2002 Senior Operations Engineer

Develop and direct manufacturing equipment maintenance programs,

conceive and implement productivity projects, integrate "demand

flow technology" into the production operation and promote the Six

Sigma culture throughout the manufacturing operation.

. Developed quick-change heads reducing bottleneck process

changeover cycle by 2 days. Applied "demand flow" principles,

reducing unplanned downtime by 15% and cutting in-process losses

50%

. Conceptualized and demonstrated viability of manufacturing low

wattage metal halide arc tubes on TOW-idled high volume halogen

filament tube manufacturing system. Team-effort generated $2MM

in cost avoidance, $800M in labor productivity, and $2.4MM in

volume margin. GE Patent award.

. Team effort: Developed curriculum and trained 300 hourly staff

in fundamental Six Sigma techniques

ASSOCIATED MATERIALS - ALSIDE WINDOW DIVISION - AKRON, OHIO

Alside was the first company to manufacture and market pre-painted

aluminum siding in the late 1940's. Their business model overcomes the

seasonal nature of the home improvement market by distributing

nationally, focusing on warm southern markets during the winter, and

northern markets in the summer.

1989 -1994 Lead Manufacturing Project Engineer

Spearhead technical innovation at three production facilities.

Implement cost reduction and continuous improvement projects, and

integrate information technologies into manufacturing operations.

. Reduced extrusion losses by $400M annually by developing NC cut-

to-length saw.

. Sourced and installed NC glass cutting system, reducing labor

content by $275M.

. Invented NC router system to manufacture diamond grid muntins

inside insulated glass units.

. Developed algorithm and wrote software to auto-design bay window

seatboards, based on customers supplied parameters. Quadrupled

plant's ability to serve a high-margin market.

GENERAL ELECTRIC COMPANY - LIGHTING BUSINESS - RAVENNA, OHIO

1987 -1989 Advanced Process Engineer - Projects

Conceptualize, develop, and implement flexible automated and semi-

automated manufacturing systems

1984 -1987 Specialist, Methods and Work Measurement

1981 -1983 Engineering Co-op

Education

UNIVERSITY OF AKRON - AKRON, OHIO

1978 - 1983 Bachelor of Science, Mechanical Engineering

Additional Training

Motion Time Survey GE Corporate

1984

Occupational Ergonomics University of

Michigan 1985

Japanese Manufacturing Techniques GE Lighting

1986

Six Sigma - GreenBelt Training GE Lighting

1997

Six Sigma - BlackBelt Training GE Lighting 2002-2003

Lean Manufacturing BootCamp - Shingijutsu GE Medical

Systems 2003

Team Leader - Lean BootCamp - Shingijutsu GE Consumer /

Industrial 2004

Event Director - Lean BootCamp - Shingijutsu GE Consumer /

Industrial 2006

Proficiencies

. GE certified Black Belt in Six Sigma methodology; Green Belt instructor

. Licensed Professional Engineer: State of Ohio 1991 - 2007

. PC skills: advanced MS Office, especially Excel and PowerPoint, Minitab,

AutoCAD, Visio, machine controls

. Diversified engineering experience: industrial, mechanical, manufacturing

engineer, project management

. Strong creative aptitude: "thinking outside of the box"

Eugene

A. Smith

2 of 2

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