Manager Six Sigma

JEREL T. RUMBLEY, MBA, MBB

**** *******, **** ****, ** 63119

414-***-**** - abmk2s@r.postjobfree.com

SR. EXECUTIVE - OPERATIONS AND LEAN SIX SIGMA

Consummate Operations Executive - Progressive leader with proven background

in enhancing financial and operational performance for diverse businesses.

Adept at leading multicultural workforces in deliverance of world-class

safety, quality, productivity, and service. Strategic and tactical planner

experienced in scanning markets and implementing value added projects.

EBITDA and Working Capital driver astute in financial analysis and cost

control of operating expenses, inventory levels, capital projects, and

SG&A.

Motivated Change Agent - Energetic manager of change with ability to

identify cost drivers and their respective opportunities for enhancement.

Relentlessly seeks and minimizes operational waste, process variation, and

financial variances. Architect of numerous multi-million dollar turnaround

projects in the automotive arena with excellent results. Highlighted areas

of expertise:

( P&L Management - $100 Million+ ( Budget Development &

Cost Control

( Multi-Facility Management (30 Plants) ( International

Ops - China, France, Mexico

( Operational Turnaround ( Strategic & Tactical

Planning

( Lean Six Sigma Master Black Belt (SBTI) ( Toyota Production

System (YOMO)

( Quality Management Systems - ISO/TS ( Global Product Management

( Associate Development & Labor Relations ( ERP & Inventory

Management

SPARTECH PLASTICS, Clayton, Missouri

Billion dollar sheet plastic extrusion, color concentrate compounder, and

packaging technology manufacturing organization serving automotive,

recreation and leisure, building and construction, sign, and food

packaging markets

DIRECTOR OF OPERATIONAL EXCELLENCE, QUALITY, AND ENGG (8/08

- present)

Reports - 6 Direct (2 Dir of QA, 2 Dir of Engg, 1 Regional QA Engr, 2

Reg QA Mgrs) and 150 Indirect+

. Corporate Leader of Lean Six Sigma, Quality, and Process

Engineering - accountable for customer returns, cost savings,

internal first time yield, and OEE in Americas, France, and

Canada

. Spearheading Global Lean Six Sigma and Continuous Improvement

Deployment Initiative for 30+ operations yielding 24 trained Black

Belts and $6.5 million in verified savings in 16 months

. Chief Architect of Corporate Wide $950 million operating budget for

30 operations with associated cost savings targets, project

execution, and tracking methods

. OEE Enhancements throughout the organization via addressing

mechanical integrity, critical process variable optimization,

and technological defect detection systems - 7% overall

increase

. Managing Customer Response system for product returns,

specifications determination, and root cause and corrective

actions methods - reduced normalized returns by 16% from 2008 to

2010

TYCO ELECTRONICS / CIRCUIT PROTECTION, Milwaukee, Wisconsin

$60 MM pPTC fuse manufacturing operation with 110 associates serving

diverse markets including Telecom, Battery, and Automotive - with Global

Deliveries to Shanghai, California, Japan, and Europe - technologies

include: CNC drilling, imaging, and plating

PLANT MANAGER - pPTC Fuse Operation (5/06

- 8/08)

Reports - 6 Direct (Mgrs. / Production, QA, Engg, Production Control,

Purchasing, EHS) and 104 Indirect

. Advanced Productivity by 16.4% units/labor hours '07 Q2 to Q3

- using standard work observation techniques and direct labor

balancing : achieved above budgeted level on gross profit %

. Championed Lean Six Sigma Program - setup program structure,

trained 60 associates in techniques and mentored 6 Belts in

project execution - delivered savings of $220k via 31% reduction

in copper plating variation

. Flawlessly executed an Executive Strategic Plank of protecting

miniSMD panel supply through specifying, procuring, and installing

capable production systems - $1.25 million of capital equipment

was installed and qualified at 1.33 minimum Cpk process control

. Reduced Work in Process (WIP) 40% in 3 months - utilized visual

pre-process kanban racking system : customer delivery improved 30%

from this project

. Led Cross-Functional Team in New Product Launch - product was

hybrid over voltage & overcurrent protection : project was

delivered on-time and within budget

TDS/US AUTOMOTIVE, Chesapeake, Virginia

$850 MM throughput 3 FACILITY TIER ZERO sequencing and bulk metering center

for Ford Norfolk Assembly Plant - ISO9001:2000 and AIAG MMOG level 'A'

certified. This UAW Shop was 460,000 sq. ft. under roof with a 6 acre

Frame Yard.

PLANT MANAGER - Multi Site Sequencing Center (11/04

- 5/06)

Reports - 7 Direct (Mgrs / Ops, QA, MP&L, Facilities, Lean, HR,

and Accounting) and 300 Indirect

. Successfully Managed 36 commodity JIT operation with annual

deliveries of $850 million to Ford Norfolk Assembly Plant -

achieved financial performance better than budgeted level

. Facilitated 100% On-Time Launch of All Components for 2006

vehicle pre-builds

. Developed U-Cell Concept for Lean Container Management System -

eliminated $350k in cost from work cell movement, transportation,

and damaged component processes

. Led Team to Successful Implementation of ISO 9001:2000 - Certified

May '05 [PPM < 15] thoroughly enhanced customer compliant

corrective action process

. Supervised Team through the Materials Management System

Certification - Ford/AIAG MMOG Level 'A' Achieved April '05 :

yielded 45% reduction in non-conforming shipments

. Customer Satisfaction Rating Improvement - [ 2nd Qtr 2005:

+22.3% / 1st Qtr 2005: Baseline ]

Through collaborative metrics, frequent communications, and

corrective action execution

MERIDIAN AUTOMOTIVE SYSTEMS, Detroit, Michigan

$50 MM TIER ONE supplier of expanded polypropylene (EPP) energy absorbers.

Certified in TS16949, ISO 14001 and Q1. This 280,000 sq. ft. UAW plant had

154 associates. Recipient of 2 Chrysler Gold Pentastars / 4 GM Supplier of

the Yr Awards (97 - 00).

GENERAL MANAGER - Plastic Molding & Assembly Operation

(5/01 - 11/04)

Reports - 8 Direct (Mgrs. / Controller, HR, Ops, QA, Logistics,

Facilities, EHS) & 146 Indirect

. $50 Million P&L Responsibility - managed all plant functional

departments, derived capital justifications, facilitated labor

relations, priced all products, and interacted with customers

. Improved EBITDA - [ 2003: +7.5% / 2002: +12.2% / 2001: +10.4% /

2000: Baseline ]

Won Plant Manager of the Year in 2003 for outstanding

performance

. Championed Toyota Production System - Productivity Gain [ 2002:

+11.1% / 2001: Baseline ] Achieved via standardized work, error-

proofing, quick changeover, TPM, and pull systems

. Supervised 4 Domestic and International Sub-Contractors ($20 MM

Revenue) - monitored their quality systems, capacity

utilization, training programs, and supported them in design

change processes

. Developed 4 Bottom Up Operating Budgets (with Cost Reductions

Plans) for 2002 - 2005 included plans for headcount, material,

capital, operating expenses, development, SG&A, and cost

reductions

OPERATIONS MANAGER / COST ESTIMATOR (1/01 -

5/01)

Reports - 4 Direct (Production Supervisors & Process Engineer)

and 75 Indirect

. Maintained Excellent Metrics - 2004 & 2003 QA PPM [< 20] and 2003

Delivery Rating [97%+] achieved via project management, associate

involvement, and waste identification & elimination

. Managed All Production Department responsibilities including -

associate orientation, training, standard work procedures, QMS

execution, yield enhancement, and associate accountability

. Developed Costing Model for Pricing New and Incremental Business -

model was used by sales force to instantaneously deliver customer

feedback based on static product specifications

. Developed MS Access Production Database for Tracking Lean Process

Metrics - data was used as a precursor for our performance

management system

PRINTPACK, INC., Hazelwood, Missouri

$80 MM Unionized Flexible Packaging Plant servicing a broad range of

markets (pet nutrition, snack foods, chemicals, photo film, labels, etc.).

Responsibilities included: oversight of an entire shift - 4 Flexo & 2

Gravure Presses, 4 Laminators, and 7 Slitters.

SHIFT MANAGER - Flexible Packaging Operation (8/98

- 11/99)

Reports - 4 Direct (Supervisors) and 75 Indirect

. Oversight of All Shift Activities - Safety, QA, waste,

productivity, and processing

. Responsible for $20 MM budget, projects, and extrusion

process control

. Manufacturing representative for Nestle Beverage account (15%

of gross sales)

VAN LEER FLEXIBLE PACKAGING, L.P., Houston, Texas

Subsidiary of $3 billion International Packaging Corporation Van Leer

Corporation. Producer of specialty HDPE Cross-Laminated Film (Valeron).

Responsibilities included - Improving Productivity for 2 ext. laminators, 1

Flexo Press, 7 Blown Film Lines, and 2 Slitters.

PROCESS ENGINEER / EXTRUSION SUPERVISOR (6/96 - 7/98)

. Responsible for quality consistency improvements & productivity

. Technical assessor for OEM equipment for new extrusion laminator

. Created process specifications for each product line

EDUCATION

WAYNE STATE UNIVERSITY, Detroit, Michigan

Master of Business Administration (MBA) - Finance (GPA - 3.7

/ 4.0)

Bachelor of Science - Chemical Engineering (GPA - 3.2

/ 4.0)

SEMINARS & TRAINING

. Six Sigma Master Black Belt Program 2008

. Six Sigma DMAIC Black Belt Program 2007

. SkillSoft - "Mark of a Leader" and "Managing in Crisis"

2006

. TS 16949 QA Standard Training by SRI Registrar

2003

. A3 TPS Training - Lean Planning

2002

. Lean Concepts / Theory of Constraints - GM University

2001

. YOMO Toyota Production System (TPS) - Lean Training

2001

. Six Sigma DMAIC Black Belt Training 1999

. Printpack HRD Training - Leadership & Performance Mgmt

1998

COMPUTER & SYSTEMS SKILLS

Proficient - MS Office Suite, Oracle 11.5, MAPICS, SAP R/3,

Minitab 15, Windows XP, AS/400

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