Six Sigma Engineer

Muralidharan Mariappan

Objective

To use and challenge my diverse continuous improvement background, while

providing new learning opportunities

Summary of

Qualifications

1. Ability to integrate various improvement methods like Lean, Six Sigma,

Problem Solving, and Quality Management Systems, using Change Management

into business organizations.

2. Trained in Lean thinking by Shingijutsu Consultants - Sensei from

Toyota, Japan.

3. Certified Six Sigma Black Belt and various other certifications in

Quality. Saved more than $500K in black belt projects.

4. Mentored more than 20 Greenbelt projects with annualized savings of

about $400K.

5. Taught more than 75 Six Sigma Green Belts (DMAIC, Lean Six Sigma & DFSS)

in 4 waves of Greenbelt classes.

6. About 15 years of Continuous Improvement implementation experience in a

variety of manufacturing and Service environments - Pharmacy Benefit

Management industry, FDA regulated products, High-Volume automotive

products, High-Mix/Low Volume and High-Mix / High-Volume environments.

Work

Experience

Express Scripts, St. Louis. Missouri - March 2010 - Present - A Fortune 100

company providing Pharmacy Benefit Management services to employers of

various sizes and the government.

Senior Manager - Process Improvement - Client Services Quality

Supervising Quality Control department that is involved in root cause

analysis and driving strong countermeasures to incidents that affect the

clients financially.

. Leading the implementation of Strategy Deployment within the department

. Mentoring 2 Greenbelts in the department

Bausch & Lomb, St. Louis. Missouri - Jul. 2006 - Aug. 2009 - Manufacturer

of FDA Class 1 & Class 2 Surgical medical devices.used in eye surgery.

Process Excellence Site Champion

Perform the role of a Sensei to coach and lead the site's Lean journey and

responsible for the overall deployment of Six Sigma for the site. Provide

subject matter expertise and change agent skills for the management team

for the 2 manufacturing sites in St. Louis.

. Site representative for a 4-Walls Cost competitiveness analysis &

improvement project with the help of operations management consultants

from A.T. Kearney.

. Coached direct-labor level to staff level teams on A3 problem solving

methodology to create a culture of daily problem solving in the

organization

. Led the implementation of Standardized Work by coaching direct-labor

teams to agree and standardize on one best way to do a job.

. Implemented Leaders Daily Management by coaching the supervisors and

managers to audit and support Standardized Work with a Leaders Daily

Management audits.

. Led the Policy Deployment / Hoshin Kanri initiative at the site. This

served as a pilot for the entire global organization. The successful

implementation led to the global roll out across the organization within a

year - 4 levels of cascading policy deployment with action plans,

scorecard, reviews and countermeasure plans.

. Facilitated the creation and functioning of 3-value stream organizations

and mentored the value stream managers.

. Led the deployment of Lean Six Sigma program at the site. Served as the

six sigma subject matter expert and led the six sigma steering team for

the site.

. Responsible for leading the Lean Six Sigma steering team to decide on

project portfolio and pipeline, green belt candidates and overall

administration of the green belt certification program at the site.

. Member of the corporate Lean Six Sigma Deployment team.

. Taught a wave of greenbelt class consisting of 23 students.

. Mentored and certified 12 Greenbelts. Coached 12 six sigma greenbelt

projects with more than 200K in savings and improvements to non-financial

metrics.

. Led the implementation of TWI (Training Within Industry) to standardize

internal training methods. TWI is an important component of Toyota

Production System.

. Led numerous kaizen events in variety of areas - machine shop setup

reduction, Assembly cycle time improvements, accelerate new product

development, Improve product servicing effectiveness, improving the IT

platform for service organization etc.

. Led the implementation of 5S program across manufacturing, warehouse and

office areas with regular audits.

Greenlee Textron, Rockford, Illinois - Jan. 1997 - Jul. 2006 -

Manufacturer of

Electrical Construction Tools utilized in Non-Residential Construction

Certified Six Sigma Black belt (Aug. 2004 to July 2006)

Certified Textron Six Sigma Black Belt responsible for leading improvement

teams and work projects across the business as part of the Textron Six

Sigma initiative. Completed cost reduction and efficiency improvement

projects during the full time two-year assignment as a Black Belt.

. Recognized as "Top Gun" Black Belt in Textron organization for

exceptional project savings, leadership, teamwork, and execution.

. Reduced operational costs by $500K in one year as a Black Belt.

. Taught Greenbelt training courses for DMAIC, DFSS and LEAN tracks.

Mentored 9 Greenbelt projects to achieve annualized savings of more than

$200K.

. Coached three kaizen events working with a Sensei from Japan -

Shingijutsu (Former Toyota employee)

. Led 3 plant level value stream mapping exercises to identify waste

reduction opportunities and managed the 90 day project execution.

. Assist Project Champions and Business Unit Deployment Champions in

identifying and prioritizing opportunities to improve customer

satisfaction, increase net income, enhance productivity, and further

employee performance throughout the business unit.

Work

Experience

(cont.)

Plant Engineering & Quality Assurance Manager (Mar. 2002 to Aug. 2004) -

Promoted

Responsible for managing all technical support functions at 200 employee

plant covering 2 facilities reporting to the Plant Manager. Managed and

directed all aspects of Industrial engineering, Manufacturing engineering,

Maintenance, Quality and Safety program while ensuring that the functions

met the Plant's goals.

. Managed 7 direct reports, who in turn managed 20 hourly employees.

. Converted a process based plant to lean cellular layout in a low

volume/high mix environment involving more than 30 machines consisting of

4 value streams

. Assisted in shutting down another 100 person manufacturing facility and

merging the processes, products and systems with about 30% increase in

volume but with less than 10% additional personnel

. Managed the cost reduction program resulting in annual cost reduction for

the department in excess of $900,000 every year.

. Management representative for the plant quality system registered to

ISO9001:2000

Senior Industrial Engineer (Jul. 2000 - Feb. 2002) - Promoted

Responsible for physical layout, routings and time standards, standard

costs, cost variance and burden absorption analysis. Provided capacity

planning, cycle time and productivity analysis for the plant. Exposure to

CNC machining, GMAW welding, powder paint, heat treat, black oxide and

high pressure hydraulics assembly.

7. Achieved more than $150,000 cost savings and 75% reduction in lot

size/lead time by implementing a 3 lathe cell with one robot.

8. Member of the plant inventory reduction team that reduced inventory by a

million dollars by rationalizing lot sizes and lead times.

Quality Engineer (Jan. 1997 to Jul. 2000) - Promoted

Responsible for quality planning on new products and processes. Conducted

internal quality

audits and supplier audits. Managed a calibration lab containing 5000

gages.

. Reduced plant scrap and rework dollars by 30% in 3 years

. Implemented a quality planning system encompassing Design for

Assembly/Manufacturing

Reynolds Wheels International, Beloit, Wisconsin - Jan. 1995 - Dec. 1996 -

Tier 1 supplier of Aluminum Alloy Wheels to GM/Ford & Chrysler

Work

Experience

(cont.)

Quality Engineer - Machine Shop

Responsible for creating control plans, FMEA's, SPC, GR&R and PPAP for

machining aluminum alloy wheels. Responsible for adequate staffing of

quality assurance personnel for 24/7 operation involving 18 CNC machines

in 6 production lines.

9. One of the first 20 employees hired to change over from a shoe factory

to a modern aluminum wheel plant making 100,000 wheels/month, half million

square foot production space and 50 million dollars in annual sales in

less than 2 years.

Caterpillar India, Hosur, India - Jul.'90 to Jul.'91- Manufacturer of High

Power Diesel Engines for construction and power generation in India

Graduate Trainee Engineer

Responsible for process planning for machining Caterpillar diesel engine

components

Education

Master of Science (Industrial Engineering)

1994 Wichita State University, Wichita, Kansas

Bachelor of Engineering (Mechanical Engineering)

1990 PSG College of Technology, India

Additional Training

. Change Management Facilitator Training - 2006

. Certified Six Sigma Black Belt (CSSBB) by American Society for Quality

Current Professional Certifications / Memberships

. Certified Textron Six Sigma Black Belt by Textron, Inc.

. Certified Manager of Quality & Organizational Excellence (CMQ&OE) by

American Society for Quality

. Certified Quality Engineer (CQE) by American Society for Quality

. Certified Quality Auditor (CQA) by American Society for Quality

. Senior Member of American Society for Quality

. Member of Alpha Pi Mu - Industrial Engineering honor society

1393 Hunters Hollow Court

Eureka, MO 63025

636-***-**** Home

636-***-**** Cell

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