Six Sigma Engineer

RICHARD E. DUKES

**** *********** **. *******, ******* 35601 Phone: 615-

***-**** *****: ****.*****@*****.***

Lean Six Sigma Leader

-International experience improving business results-

. Global Business Strategy

. Project Management & Budgeting

. Global Supplier Management

. Lean Certified

. Value Stream Mapping

. Kanban, Kaizen, 5-S

. Black Belt Certified

. SMED Analysis

. Plant Layout (AutoCAD)

Executive Experience

Entrepreneur with track record of driving financial results through Lean

Six Sigma process improvements. Developed the expansion strategy and

quality control program for the Asia division crossing multiple cultures

and languages. Managed multiple Lean/Six Sigma projects for several

companies as an employee and consultant in continuous flow, batch processes

and remanufacturing. Expert in leading the Lean/Six Sigma training and

implementation in four countries. Delivered over 20 million dollars in

operational savings projects in 4 years.

Professional Experience

Director of Continuous Improvement, Asia Division

October 2008 to November 2009

Honest Century LTD, Lai Chi Kok, Kowloon, Hong Kong (cell phone-reverse

logistics)

. Direct report to the CEO and executive VP staff

. Managed the Hong Kong/Mainland China operations with a staff of 90

. Developed and implemented business strategy to improve and expand Asia

operations which supplied cell phone assemblies to North America and

other global customers.

. Global material sourcing and contract negotiation

Negotiated prices, quality, terms with 15 suppliers in Shenzhen, China

Hired/trained Shenzhen procurement & quality team

. Asia supplier management for production, quality and continuous

improvement

Reduced cycle time by 33%

Drove Supplier FTQ from 80% to 95%

Improved the end user reship rate from 4.7% to 2.1%

. Developed the controls for seamless and transparent systems integration

of Asia Operations with New York

. Interfaced daily with the customer's executive staff on quality,

production scheduling and increasing sales

. Reduced monthly inventory holding 35% while increasing inventory turns

and improving PI to +99%

. Developed Failure Analysis team to quickly analyze technical problems and

driving solutions

. Designed layouts for two factories in China, one in Philippines and Hong

Kong

. Traveled over 175,000 miles in 12 months

Continuous Improvement Engineer/Senior Supplier Quality Engineer

July 2005 to October 2008

Asurion Inc., Nashville, TN

~ $20B Mobile phone insurance, high-tech reverse logistics and supply chain

. Managed quality of $350 million run-rate of over 400 products

Record savings of $1 million dollars a month through Quality Initiative

Program

Traveled extensively to audit process flow, quality, corrective actions

and ISO 9001 compliance

Trained all suppliers in RF testing and Root Cause analysis setting up

FMEA procedures

Reduced functional and regulatory reship defects by 94%

. Saved $4M in 14 months, 50% through new production layout, saved over

20,000 sq. feet with zero loss time

Produced $650 thousand dollar annual savings by designing RF project with

a 5 month ROI

Produced $350 thousand dollar annual savings in the average equipment

cost (AEC) through IT improvements

Delivered $1.2 million dollar annual savings by redesigning QC process,

7% overall improvement in FTQ

. Responsible for successfully leading the Lean/Six Sigma transformation

Black Belt trainer, achieved four Greenbelt and 5 Lean certifications

Lead a team of continuous improvement engineers

. Managed the production design/implementation through 300% growth

. Reduced WIP from 20,000 plus to 2,500 through the use of:

Value Stream Mapping, Visual Factory, 5-S implementation

. Improved RF first pass yield from 81% to 92% using Gage R & R,

Fishbone, FMEA and DOE

Reduced rework by over 300% in technical repair

Increased Throughput 32%

Reduced reshipment by 27%

. Developed Kanban inventory and production management system

Connected Kanban to global MRP system

Increased production by 19%

Reduced inventory 25%

. NPI analysis team leader

Engineering/Continuous Improvement Manager,

September 2003 to June 2005

Standard Register, Murfreesboro, TN

. Managed $1.25 million dollars of capital improvement projects with zero

loss time production: HVAC roof top change out (7), Humidification, Plant

Lighting, Recycling

. Deployed Lean Manufacturing strategy, instructed all plant leadership

team and production associates with Lean techniques: 5-S, Kaizen,

Kanban, JIT, Value Stream Mapping, SMED and Visual Factory

. Annual savings of $500 thousand from Lean/Six-Sigma projects through

equipment layout designs for increased throughput and capacity

. Employed FMEA, DOE, Root Cause Analysis, Gage R & R, TPM tools

. Trained 3 associates to achieve Green Belt certification

. Increased warehouse capacity 40% by creating Kanban market lanes, reduced

WIP and increased inventory turns by 30%

. Developed Recycling Department into profit center through batch

processing and lean design

Graduate Assistant, Middle Tennessee State University

June 2003 to December 2004

. Designed, fabricated, assembled Allen-Bradley SLC/500 trainers using CAD

and Universal Laser Systems

. Assisted Professor in teaching PLC class and laboratory

. Researched 3D modeling equipment and software for advanced manufacturing

class

President-self employed, Dukes Construction, LLC; Huntsville, AL and

Murfreesboro, TN 1991 to 2002

. Managed multiple projects in different cities

. Translated engineering drawings into individual subcontractor projects,

vendor specifications and scheduling

. Managed operational budget; forecast, estimating, contract negotiations

and P & L

. Developed customer relationships to improve quality, cost and delivery

. Average cycle time of 3 months compared to national average of 5

. Secured private and institutional funding for product development.

Structural Engineer, The Boeing Co., Huntsville, AL

1988 to 1991

. Responsible for Finite Element Analysis (FEA), Structural analysis and

CAD modeling design of the Space Station Freedom Recognized by

executive management for exceptional analysis on bulkhead and hatch.

CAE tools included CAD, NASTRAN (FEA), PATRAN and I-DEAS.

Education

M.S. Manufacturing, Middle Tennessee State University, Thesis: Value Stream

Mapping, December 2004

B. S. Mechanical Engineering, Auburn University, March 1988

Lean Manufacturing Certified (Middle Tennessee State University)

Six Sigma Black Belt Certified (Standard Register-GE program/Middle

Tennessee State University)

Financial Consultant Series 7 & 63

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