Engineer Six Sigma

WILLIAM RUSS

P.O. Box *** - Easton, PA ***** - Mobile: 404-***-**** - ********@*****.***

PROFILE

Unique combination of technical skills, leadership, manufacturing

experience and business knowledge in chemical and material processing

environments with expertise in:

. Operations

. Process

. Cost

. Quality

Major contributions at all positions and companies. Six Sigma Black Belt.

Strong experience in motivating employees (direct and indirect reports).

Strengths include planning, logistics, leadership and execution.

EXPERIENCE

RSI Silicon Products, Easton, Pennsylvania 2008 - present

RSI is a start-up energy materials company providing solar grade silicon

via an unconventional, proprietary process at 33% of conventional product

cost. The 25 employee facility is the center for prototype plant

operations, R & D and manufacturing process development.

Director of Manufacturing, 2009 - present

Managed ten direct reports: two salary (Research Engineer and Maintenance

Manager), seven hourly (operators and mechanics) and one full time

consultant. Led all aspects of the manufacturing process and process

optimization. Promoted in July and report directly to the CEO.

Key Accomplishments:

. Optimized process flow from raw materials to finished product.

. Scheduled employees on 24 hour coverage based on workload and

business needs. Creative scheduling reduced overtime costs and

saved in excess of $200,000 per year.

. Established procedures and benefit versus effort criteria for

performing furnace experiments designed to achieve customer

requirements, optimize the manufacturing process and maximize

yields.

. Contributed key ideas at senior staff meetings, guiding the

direction of the company, establishing goals and documenting

milestones.

. Completed performance reviews, disciplinary corrective actions and

new employee hiring and training.

Senior Process Engineer, 2008 - 2009

Managed four direct reports (Process Operators). Directed all aspects of

the silicon manufacturing process and process optimization, including

submerged arc furnace operations, raw material preparation and designing

experiments applying Six Sigma methodology.

Key Accomplishments:

. Quickly mastered technology in a new field.

. Directed, evaluated and optimized furnace experiments. Used data

to determine process capability and measure results versus

experimental goals.

. Established exploratory furnace operating procedures,

documentation, record keeping and sample archives. Prepared

furnace trial reports for senior staff.

. Designed experiments, acquired data and analyzed results of the

production team in order to increase yields by improving process

consistency. Taught the team the importance of making decisions

based strictly on data.

. Developed master punch list for all items required to start up

prototype furnaces. Assigned tasks and set expectations with

regular follow-up to ensure furnaces were operational as scheduled.

Johns Manville (JM) - a Berkshire Hathaway Company, Winder, Georgia 1998 -

2008

JM is a leading manufacturer of premium-quality building products with

annual sales of $2.5 billion. This facility is the center of the southeast

customer base for residential and commercial building insulation.

Process Group Leader, Insulation Systems (IS), 2006 - 2008

Managed four direct reports: three Process Engineers and one Process

Specialist. Oversaw all aspects of manufacturing and process

optimization. Reported directly to Plant Superintendent and Plant

Manager.

Key Accomplishments:

. Completed rigorous four-week Lean Six Sigma Black Belt training.

. Established procedures and benefit versus effort criteria for

performing trials and technical projects designed to achieve voice

of the customer, optimize manufacturing process and maximize

throughput.

. Initiated process stability team aimed at increasing output by

improving manufacturing consistency and variation reduction. All

decisions were based strictly on data.

Senior Process Engineer, Performance Materials (PM) and Building

Insulation (BI) Divisions, 2006

Managed five-melter operation responsible for yearly outputs exceeding

200 million pounds of formaldehyde-free fiberglass insulation. Took over

melting operations after reorganization, saving the company headcount.

Reported directly to Plant Superintendent and indirectly to Plant

Manager.

Key Accomplishments:

. Highest output produced and best income from operations (IFO) in 37

year plant history. Best in PM Division. PM output increased 8% and

IFO increased a record-setting 21% from 2005.

. Initiated key operating indicator (KOI) team with weekly report to

plant staff. Meetings generated creative tension and action plans

to achieve plant targets.

. Increased throughput by 5% and 1% on two manufacturing lines

despite 33% headcount reduction.

. Six Sigma quality initiatives drove plant to exceed goals for

reduction of defects.

. Presented with "Team Turnaround" award at PM Division Leadership

conference for significant improvements made to plant performance

in 2005.

. Received two-level promotion for performance in 2006.

. Received special recognition and merit bonus in person from CEO for

1st quarter and 2005 performance. Personally led him on a

"customer-ready" plant tour.

. One direct report and 28 indirect reports.

Process Engineer, Performance Materials Division, 2004 - 2005

Improved efficiency and productivity to achieve record profits. Key

contributor to six-fold PM division IFO growth ($2 million to $13.5

million). Key contributor to record-setting plant IFO of $50 million.

Set monthly production goals to maximize plant output and keep two lines

performing at full capacity. Managed entire hot end process, including

batching, melting, fiber making, and binder application. Developed

business strategies with finance department and plant staff.

Key Accomplishments:

. Six Sigma trainer (statistics). Selected to teach for two

consecutive years. Received high accolades and highest survey

results from students after teaching the most difficult subject in

the weeklong class to a broad range of backgrounds and occupations.

. Developed process enhancements to increase melter life by 20%,

resulting in additional yearly IFO in excess of $100,000.

. Initiated major glass change for improved melting efficiency.

Output increased 8.2% and IFO increased 33% for balance of year.

. Led major forehearth rebuild: finished two days ahead of plan on a

20-day scheduled outage, resulting in bottom line impact of

$120,000. Responsible for all aspects of shutdown, demolition,

construction, checkout and startup. Unit has run flawlessly since

startup. Drain-to-startup plan became the model for all future JM

rebuilds.

. Earned merit performance bonuses for extraordinary contributions.

Process Engineer, Building Insulation Division, 1998 - 2004

Key Accomplishments:

. Coordinated, oversaw and indirectly supervised approximately 50

field personnel for melter, forehearth and fiberizer construction

and startup for new $80 million line.

. Managed more than $1 million precious metal inventory with zero

audit infractions.

. Led Six Sigma project for scrap re-feed. IFO increased $1.32

million per year. Effective control plan written to maintain

benefits. Earned Green Belt Certification.

Elan Technology, Belleville, New Jersey and Midway, Georgia 1994 - 1998

Elan Technology is a manufacturer of glass and ceramic insulators for

electrical and electronic applications. Elan also produces spray dried

glass and ceramic powders. Elan is a family-owned, customer-centric, QS-

9000 Certified business.

Key Accomplishments

. Led manufacturing relocation from NJ to GA, including major

equipment relocation and assembly, design of new, larger

manufacturing facility and developmental laboratory. Strategic

planning resulted in zero interruption of shipments to customers.

. Promoted to Research and Development Engineering Manager after only

six months as Glass-Ceramic Engineer. Directed two engineers and

four lab technicians.

. Promoted to Senior Manufacturing Engineer, responsible for all

aspects of manufacturing operations, including the tool-and-die

department.

. Directly supervised crews of up to 20 in various departments

(Operations, Quality, Maintenance and Engineering).

EDUCATION

M.S., Materials Science and Engineering, Virginia Tech, 1994

B.S., Ceramic Engineering, Rutgers University, 1991

CONTINUING EDUCATION / TRAINING / ACTIVITIES

Lean Six Sigma Black Belt

Dealing With Conflict and Leadership Foundations

Myers-Brigg Type Indicator Training and Assessment

Max-Q Flawless Execution Leadership Conference (by special invite from CEO)

Six Sigma Green Belt Instructor

Six Sigma Set-up Reduction

Six Sigma Green Belt

Statistical Process Control

Franklin-Covey What Matters Most

Easton Farmers' Market volunteer

Lehigh Valley Professionals

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