Manager Manufacturing
Resume:
GARY BROWN
*** ******** *****, **** ******, IL **118
*********@***.***
PROFILE
Passionate, personable Manufacturing Executive with strong track record of
operations turnaround and profit/cash flow improvement in High Tech
industries. Utilized "hands on" shop floor management style to identify
and achieve $4.2M in cost savings, while improving production metrics and
customer satisfaction. Key strengths in root cause analysis, creative
problem solving and executing programs on time and budget. Collaborative
organizational style, resulting in customer partnership, team building and
individual accountability. Skilled in:
Lean Manufacturing/Cost Change Agent
Reduction
Continuous Improvement Advocate Project Management
Team Building/Personnel New Product Launches
Development
Structured Problem Solving Kaizen/6S Disciplines
Value Stream Mapping Green Initiatives
PERFORMANCE SCORECARD
. Directed and obtained RoHS compliance for major product that reduced
costs and resulted in Joint Venture profit turnaround - Director of
Operations: Cardiac Science Corp
. Identified and implemented $1M/yr lean manufacturing projects, reducing
costs by 8% of overall operating budget - Director of Operations:
Cardiac Science Corp
. Implemented Kaizen events that saved $275k, improving quality, reducing
credit memos, and improved on-time delivery - Plant Manager:
Rockwell Automation
. Installed a "Clean Room" operation for making LCD touch screens that
expanded manufacturing capabilities essential to capturing $525k new
customer business - Director of Operations: SigmaTron International
. Implemented a shop floor level continuous improvement project to reduce
product changeovers by 78% and increasing overall capacity utilization by
28% - Director of Manufacturing: Microelectronics Modules Corp
. Developed 15 process improvement teams that produced savings of $3.2M -
Process Improvement Manager: 3COM
PROFESSIONAL EXPERIENCE
CARDIAC SCIENCE CORPORATION, Deerfield, WI 2006 - 6/2009
ISO 9001 and ISO 13485, Class 3 medical device manufacturer of automatic
external defibrillators, electrocardiographs and cardiac rehabilitation
systems. Site assembles electro-mechanical and computer based medical
products, tests and ships products to end customers and distributors using
six unique manufacturing cells.
Director of Manufacturing
Reported to VP Operations. Recruited to implement Lean Manufacturing
methodology. Responsible for manufacturing engineering, production,
test, shipping and receiving and facilities with nine direct reports
and total workforce of 75. Worked closely with Design Engineering to
improve existing manufacturing process and improve new product
introduction. Supervised manufacturing engineering and test
engineering to reduce manufacturing defects and improve test coverage.
Corrective and Preventive Action (CAPA) team member assigned to
resolve open manufacturing CAPAs. Worked closely with the Service
Department to determine root causes of field failures and determine
what changes that could be made to eliminate future failures.
Developed department metrics that were reviewed and posted daily by
every department. Managed $8M operating budget and $2.8M annual
capital plan.
. Improved first pass yields by 30% and saved $252K annually in
rework costs through use of Pareto analysis and organization focus
on top three opportunities.
. Developed print on demand solution for instruction manuals, gaining
200 sq. ft. of storage space, and reducing lead time by 92% and
costs by $250K annually.
. Created a shop floor visual monitoring system that enhanced
manufacturing efficiency, FPY, and customer visitation appeal.
. Led team to meet customer selection criteria for Green
Manufacturing by reducing annual energy consumption by $12K, waste
stream costs by $2K, packaging material by 70K lbs. and shipping
costs by $27K.
ROCKWELL AUTOMATION, INC., Ladysmith, WI 2005 - 2006
The largest manufacturer of industrial control products and solutions for
industry. This ISO 9001 registered site is a competitive configure to
order manufacturing location that builds mechanical and electro-mechanical
parts to order and to stock.
Plant Manager
Managed $14M operating and $1M capital budgets, Directed 190 employees
and six direct reports in manufacturing engineering, quality,
planning, human resources, assembly and molding operations. Shipped
450k orders/year, totaling 900K pieces. Worked with site and corporate
engineering to successfully transfer products into and out of the
facility. Reported to VP Manufacturing.
. Utilized multiple Lean Manufacturing techniques to reduce costs,
resulting in $1.2M favorable absorption variance.
. Established "Visual Shop" environment with floor metrics that
increased first level management response, yielding a 6% gain in
production efficiencies.
. Reduced manufacturing lot sizes which reduced raw inventory by 3%,
netting $450k reduction in inventory.
. Added incremental molding plant volume due to lower overall plant
net cost.
SIGMATRON INTERNATIONAL, INC., Elk Grove Village, IL 2001 - 2005
This ISO 9001 registered site of an electronic manufacturing services
provider assembles product and box builds for telecommunications, power
transmission, appliance, and gaming and fitness industries.
Director of Operations
Recruited to improve operational efficiency and reduce costs.
Accountable for P & L at this location and for purchasing, program
management, customer quotes, human resources, manufacturing, quality,
and facilities. Successfully worked with customers to implement
product transfers and new product builds. Reported to VP Operations.
Managed 5 direct reports with total plant workforce of 165.
. Established a "Customer and Operational Center" that increased
customer order focus, resulting in improving on time shipments from
65% to 96%.
. Improved on-time delivery for a major customer to 96% and vendor
quality to 97% resulting in Platinum Award and preferred vendor
status.
MICROELECTRONIC MODULES CORPORATION, New Berlin, WI 2000 - 2001
Reported to VP Operations. An ISO 9001 contract manufacturer which
supplied microelectronic packaging design, assembly, test and manufacturing
services for the communication, medical and computer markets.
Director of Manufacturing
Hired to turnaround losing operation. Responsible for staff of eight
salaried and 180 union employees in a gain-sharing environment.
Managed assembly operations of surface mount, die mounting, wire
bonding, testing, prototype introduction, build plan development,
process improvement and capacity requirement planning. Successfully
trained employees on how to use lean manufacturing techniques which
reduced changeover time, improved first pass yields and reduced scrap.
. Leader in adopting a gain sharing program that created incentives
for improved operation performance, resulting in a culture change
fundamental to return to profitability.
. Included shop floor personnel in Kaizen events and made equipment
improvements, which reduced changeover time by 78%, and improved
manufacturing efficiencies by 30%.
. Established a project team to improve customer satisfaction,
improving on time delivery by 95% while reducing order to cash
cycle by 25%.
3COM, Mount Prospect, IL 1995 - 2000
An ISO9001 registered corporation that designs, manufactures and markets
business networking, remote access and wireless solutions for carriers,
consumers and service providers.
Process Improvement Manager, Carrier & Personal Products Division
(1998 - 2000)
Reported to the Director of Manufacturing. Responsibilities
encompassed developing, implementing and managing the first process
improvement process plan for this 1200 employee manufacturing
location. Served as Supply Chain Team, Kaizen and 5S Leader.
. Implemented visual monitoring, improving efficiency by 6%, reducing
WIP by $1M and increasing FPY by 6%.
. Developed Process Improvement Training for Sponsor and Facilitator.
. Reduced machine changeover time by 74%, increasing annual capacity
by 8.5K hours.
Customer Returns and Repair Manager (1997 - 1998)
Reporting to the Director of Manufacturing, managed processing of
$100M in annual distribution channel inventory returns, resolving
customer disputes and crediting customer accounts. Wrote rework
instructions, analyzed inventory, product demand and scrap.
. Reduced customer credit time by 66% to one day.
. Developed a returned product process that identified resalable
items and reduced dollars in credit inventory by 60% while
increasing inventory space by 10%.
Operations Manager (1996 - 1997)
Reported to the Director of Operations. Managed all night plant
operations with a staff of 7 salaried and 150 hourly employees.
Responsibilities encompassed all manufacturing operations including
maintenance, testing, system configuration, box builds, pack out and
process improvements.
. Established first cross functional review of goals for night
operations.
. Increased surface mount output by 20% and reduced scrap by 31%.
. Reduced WIP by 45% and increased FPY by 20%.
Production Manager (1995 - 1996)
Reported to the Director of Manufacturing. Managed a production line
with one direct report and 28 hourly employees. Responsible for the
manufacturing of modems-the production, test and pack out.
. Led a cross functional team which redesigned the SMT screen which
improved FPY by 6%.
EDUCATION/ASSOCIATION SERVICE
Bachelor of Science - Management, Northern Illinois University,
DeKalb, IL
President of the Midwest Chapter of the ESD Association
UW Lean Accounting Philip Crosby
Quality College
Teradyne Lean Management US Robotics Lean
Structured Problem Solving
Six Sigma Green Belt Training Minitab Statistical
Quality Training
DuPont STOP Safety Training Safety Leadership
-National Safety Council
ISO 13485 GMP and 21 CFR 820 QSR Training
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