Six Sigma Engineer

Yavuz Goktas, Ph.D.

**** ******** *****, ****, ** 16509

Phone (H): 248-***-****, (Work): 814-***-****, e-mail:

*************@*****.***

A result oriented executive quality & reliability director with

proven record as an effective leader with over 20 years of diversified

experience in the design and manufacturing of automotive parts,

electrical parts, medical devices, aerospace products, telecommunication

parts, energy and locomotive parts.

Strong leadership, change management, project management and

extensive hands-on experience with cross functional teams across a wide

array of global environments including Research and Development,

Manufacturing, Finance, Marketing, Sales, Supply Chain, Information

Services and Human Resources.

KEY TRANSFERRABLE SKILLS:

Design for Six Sigma (DFSS) Product Safety & Risk

Assessment

Design for Reliability (DFR) Toyota Production System (TPS)

Design for Manufacturability & Just-in-Time/Flexible

Assembly (DFMA) Manufacturing System

Design for Serviceability Regulatory Compliance

Six Sigma (DMAIC) Value Engineering/Value

Analysis

Lean (Transactional & Quality Systems & Standards

Manufacturing)

Supply Chain Management Change Management

Supplier Quality Organizational Alignment &

Development

APQP & PPAP Strategic Planning, Development

& Execution

Robust Design Engineering Cost Productivity

CAREER SUMMARY:

GE Transportation, Erie, PA

2008-Present

Executive Director of Quality

. Champion Operational Excellence by applying best practices in Lean Six

Sigma, DFSS and DFR and leverage resources to ensure that global

engineering technology team consisting of over 2000 engineers work to

meet quality, schedule and profit objectives.

. Drove DFSS/DFR integration and implementation into new technology

development by establishing DFSS/DFR deployment plan to meet GE

Transportation business needs. Ensuring rigor in project execution,

quality and on time deliverables of DFSS requirements in Formal Design

Reviews.

. Built DFSS/DFR competency by teaching, training, coaching and

mentoring Master Black Belts/Black Belts in the use of DFSS/DFR

methodologies.

. Led deployment of Requirements management tool using DOORS for the

business with expected annual savings of $1 M from non-recurring

engineering hours, missing/wrong requirements. Reduced order to power

cycle by 5 weeks by using DOORS as part of product configurator.

. Led institutionalization of Design for Manufacturability & Assembly

(DFMA) in the business by developing the DFMA process, training

material and incorporating it into Toll Gate process. Held several

waives of DFMA workouts with key sub-systems consisting of cross-

functional team members for major locomotive families and wind.

Reduced loco unit cost by more than $100 K with application of DFMA.

Expected savings from DFMA workouts to be around $2 M per year.

. Led Change Notice Reduction Process to reduce change notices by more

than 30% in the manufacturing floor. Systemic changes included

implementation of Automated Interference check analysis using UG

Interference Check tool integrated with DOORS, Design for

manufacturing and Assembly checklist and 3 P with expected annual

savings of over $5M per year.

. Led Reliability Practitioner Certification program within GET to raise

GET's technical competency on DFR. Certified over 50 Reliability

Practitioner across GET globally.

. Led reinvigoration of DFSS by identifying and filling the gaps in the

process and developing hands on training on the areas where the

business lacked and had quality misses which brought warranty savings

of more than 2.5 M per year.

. Led Engineering cost productivity initiative with more than 40 high

impact projects bringing over $20M/year savings.

EATON Corporation

2005- 2008

Corporate Quality, Southfield, MI

General Manager for Engineering Excellence (DfX)

. Responsible for deployment and management of Design for Six Sigma

(DFSS), Design for Reliability (DFR) and Design for Manufacturability

and Assembly (DFMA) globally at Eaton.

. Led development & deployment of a new DFSS strategy corporate wide

that:

o Incorporated DFSS Requirements into Eaton's Product Development

Process

o Included brand new two types of DFSS training as:

. DFSS Green Belt (5 days-instructor led)

. DFSS Black Belt (5 Modules- instructor led)

o Developed DFSS MBB, BB and GB Certification policy first time at

Eaton and deployed it successfully

o Established and led a corporate DFSS Council and DFSS Council

Meetings four times a year

o Delivered 14 waives of DFSS User training corporate-wide

o Developed an internal web site for DFSS.

o Trained more than 1000 engineers with DFSS around the globe.

. Led development & deployment of Corporate Design for Reliability (DFR)

Strategy that:

o Formed and led a corporate DFR Council

o Developed Corporate DFR Process

o Developed a two-day DFR workshop

o Incorporated DFR Requirements into Eaton's Product Development

Process

o Trained more than 1000 engineers around the globe

. Led development & deployment of Design for Manufacturability and

Assembly (DFMA) Strategy that:

o Formed and led a corporate DFMA Council

o Developed Corporate DFMA Process

o Developed a two-day DFMA training workshop

o Incorporated DFMA Requirements into Eaton's Product Development

Process

o Trained more than 200 engineers around the globe.

. Led top 10 new mega projects as DFSS MBB with their DFSS and DFR

requirements needs.

MOTOROLA

2003-2005

Motorola University, Schaumburg, IL

Director of Six Sigma :

. Managed corporate Digital Six Sigma Program that included training

curriculum development, deployment, and teaching of Digital Six Sigma

(DSS).

. Deployed and managed DFSS and MFSS (Marketing for Six Sigma) corporate-

wide.

. Served as a master instructor, master coach and company master expert

for Lean Manufacturing, DFSS, DMAIC and Robust Engineering throughout

Motorola

. Led the development of a four week brand new Digital Six Sigma Black

Belt program which includes a 3 week core DMAIC and one week elective

(DMAIC for Software, DMAIC for Hardware, DMAIC for Transactional and

DMAIC for Manufacturing)

. Developed Six Sigma for Hardware curriculum and deployed it

successfully at Motorola

. Developed Six Sigma for Manufacturing (Lean Manufacturing) and

deployed it successfully at Motorola

. Led Hybrid Green Belt material development, deployment and management

at Motorola

. Trained and coached more than 1000 Black Belts and Green Belts from

Design, Manufacturing and Transactional areas in DMAIC and DFSS as

well as in Lean Enterprise, Robust Design and Reliability.

. Led Steering Committee on Continuous Improvement for Six Sigma Black

Belt, Lean Enterprise and Robust Engineering and DFSS at Motorola

. Developed and managed "Certification Process" policy for Master Black

Belt, Black Belt and Green Belt Certification.

BAXTER HEALTHCARE CORPORATION

2001-2003

Transfusion Therapies Division, Round Lake, IL

Senior Manager of Reliability and Quality Engineering:

. Established a new Reliability and Quality Engineering (R&Q E) group to

support design and manufacture of a set of medical devices to inactivate

pathogens in donor blood. Expected revenue from this project is estimated

to be around $2 billion per year which is the biggest project (Intercept)

ever at Baxter Healthcare

. Recruited, managed, and developed 12 new R&Q E engineers to support

product development and manufacturing processes of the Intercept project.

Planned and scheduled R&QE support for project implementation. Managed

the R&Q E team that developed, executed, and maintained quality methods

and processes to meet the FDA regulations on safety, efficacy and

quality.

. Co-developed and successfully deployed DMAIC Six-Sigma program and

training material for Fenwal Division and trained and coached 15

executives including the President, all VPs and Senior Directors towards

their green belt certification, saving the company over $500,000 in

consulting fees.

. Developed and successfully deployed Design for Six-Sigma under the Robust

Product Development and Manufacturing Process which saved the company

more than $1 M in consulting fees.

. Co-developed extensive training materials and a work shop on "Variation

Reduction" and trained key manufacturing personnel at all the

manufacturing plants of Transfusion Therapies Division .

. Developed and successfully implemented Supplier Quality Control process

called Advanced Product Quality Planning (APQP) across Transfusion

Therapies Division with 9 SOPs to support successful implementation of

APQP . Trained R&D and Manufacturing personnel with the APQP SOPs.

Aligned these SOPs with cGMPs for both Medical Devices and Finished

Pharmaceuticals.

. Approved protocols and supported documentation (engineering change

requests, system change forms, etc.) in order to secure project release.

Developed staff members to assume technical approver role.

FORD MOTOR COMPANY

1995 -2001

North American Car Quality, Dearborn, MI

Certified Six-Sigma Black Belt :

. Completed 6 high impact Six Sigma projects with over $ 10 M savings that

were verified as hard savings by finance department.

. Trained and coached more than 1500 black belt and green belt candidates

in Six Sigma DMAIC and DFSS methodology.

. Made significant contributions to development of homegrown "Design for

Six Sigma" material as a key member of the core team.

Truck Vehicle Center Quality, Dearborn, MI

Reliability Technical Specialist:

. Drove use of reliability/quality disciplines to support forward model R

&D. Lead overall program reliability test planning, evaluation and prove-

out and implementation of FMEA/Robustness/DOE workshops

. Led development, deployment, training and coaching of "High Mileage

Reliability" for NAC department. Trained S197 project management team and

50 other NAC Waive 2 High Mileage team members and suppliers. Led 4 cross-

functional teams for high time/mileage in service customer satisfaction

improvement that exceeded the competitor's reliability in high

mileage/time for two vehicle lines.

. Served as one of the two core members of a team to develop a state-of-the

art reliability and risk assessment software that has been widely used at

Ford Motor Company right now. This software was awarded a Quality award

and saved company more than $500 K per year for consulting fees for

Reliability Assessment activity

. Led Focus Fuel Pump Failure team towards robust resolution of the

problem. 2002 MY Focus has the new Fuel Pump that was developed with my

leadership.

. Led "Rear Knuckle Failure" Resolution team which led to a successful

launch of 2001 Mustang Cobra

. Led Continuous Variable Transmission Reliability team towards designing a

robust transmission for 2004 D219/D258 program.

. Led Supplier Quality Planning (APQP) and Supply Chain Management

activities.

Powertrain Operations Quality, Dunton, UK

Snr. Reliability Engineer (on foreign assignment) :

Built Design for Reliability (DFR) competency of Puma and Lynx Diesel

Engine development group by :

. Training more than 200 R&D engineers with Design for Reliability

Toolbox series that contained 17 key DFR modules.

. Leading DFR implementation towards successful launch of Ford Fiesta,

Focus and Mondeo models that have had high demonstrated field

reliability with lowest warrant expenses since they were launched.

PTO V-Engine Quality, Dearborn, MI

Reliability Implementation Engineer:

. Led the development of 4-step concise reliability process supported by a

reliability software called "Reliability Help Disk" to support the

product design system/sub-system/component areas where no reliability

engineering support is given. This software saved Ford Motor over $500 K

per year and was awarded Customer Driven Quality Award. This software has

been widely used at Ford Motor Company now.

. Core member of a team that developed a Corporate Reliability Data System

to enter test requirements, track all required tests at vehicle,

powertrain, subsystems, and components globally, apply FRACAS and carry

out reliability assessment. This software saved Ford Motor more than $1

million dollar in consulting fees and was awarded Customer Driven Quality

Award.

. Led Reliability prediction, Target setting, FMEA, Fault Tree, FRACAS, 8D,

HALT/HASS, DOE, Robust Engineering and Growth Curve development for

engine system, engine sub-systems and critical components for 4.6 L 2v/4v

engines. This engine was successfully launched and was awarded as one of

the top 10 best engines in the world in terms of performance, quality and

durability.

. Trained and coached more than 500 design engineers with reliability

methods and tools.

OTOSAN AUTOMOBILE ENGINE PLANT-Ford of Turkey

1987 - 1989

Manufacturing & Quality Engineer:

Worked as a quality engineer to update the current work standard times,

improve the current Work Methods and Productivity Improvement efforts that

included Process Flow Chart, PFMEA, SPC, Design of Experiments, Gauge R&R,

FRACAS, Line Balancing, Bottleneck Resolution, and Production Planning

&Inventory Control.

EDUCATION:

M.BA. in Supply Chain & Integrative Mgmt. (2008)

Michigan State University, East Lansing, MI

Ph.D. in Industrial Engineering (1995)

West Virginia University, Morgantown, WV

M.S. in Industrial Engineering (1991)

Cleveland State University, Cleveland, OH

B.S. in Industrial and Manufacturing Systems Engineering (1987)

Anadolu University, TURKEY

HONORS/AWARDS/CERTIFICATES:

. GE Certified DFSS Master Black Belt

. Motorola Certified Master Black Belt

. GE Certified Reliability Expert

. Certified Lean Product/Process Development Expert

. Ford Certified Six Sigma Black Belt

. ASQ Certified Black Belt (CSSBB), Reliability Engineer(CRE), Certified

Quality Engineer(CQE)

. Two-time recipient of "Key to Success" awards at Baxter Healthcare

. Won President's Quality Award with project "Intake Manifold Hiss Noise

Elimination Team", Ford ('99)

. Won Customer Driven Quality Award with project " Corporate Reliability

Database System" Ford ('98)

. Won Customer Driven Quality Award with project " 4.6 2v Oil Consumption

Team",Ford ('97)

. Won Customer Driven Quality Award with project " Reliability Help Disk",

Ford ('96)

. Vice-Chair, ASQ National Reliability Division ('01-03)

. Member of Alpha, Pi, Mu

. Member of Sigma Beta Gamma

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