Six Sigma Master Black Belt

Michael S. Zwolinski

** **** ***** **

Colts Neck, NJ 07722

C: 732-***-**** *******@*****.***

SIX SIGMA DEPLOYMENT MANAGER

Lean Six Sigma Master Black Belt with expertise in enterprise wide Six

Sigma deployment at Fortune 100 Companies. Extensive experience with

process improvement, problem solving and business process re-engineering

using structured Lean and Six Sigma methods. Direct experience in change

management with global executive leadership teams, across multiple

organizations and customers. Demonstrated record of success in teaching and

mentoring teams to achieve results using variation reduction (DMAIC), waste

reduction (LEAN), and revenue growth (DFSS) principles.

PROFESSIONAL EXPERIENCE

DELPHI CORPORATION, Warren, OH 1997 - 2009

An $18 billion global provider of consumer, automotive, and medical

products.

Six Sigma Master Black Belt Process Manager (2008 - 2009)

Led Continuous Improvement and Innovation activities across the Engineering

function including manufacturing and transactional business operations.

Served as mentor to leadership to drive application of Lean, Six Sigma and

Design for Six Sigma methods across all business units and regions.

Established standards for certification and curriculum content as part of

corporate Six Sigma Steering committee.

. Architect for Six Sigma deployment covering all strategic aspects from

resource and talent planning through program management and project

execution.

. Trained and mentored more than 150 project teams as part of corporate

program which has trained >7000 employees and delivers >$300M annual cost

savings.

. Achieved certification of design process rigor from 4 largest customers

as condition of future business.

. Six Sigma problem resolution efforts resulted in $45M in new business.

. Received Engineering Directors award for most successful global team.

. Led Value Analysis of Product Development workflow, including future

state process design to reduce cycle time by 39%.

. Created "Quick Win" project strategy to engage 100% of staff in

continuous improvement activities.

Design for Six Sigma & Reliability Deployment Manager (2006 - 2008)

Global role to integrate DFSS and Reliability into corporate product design

process. Managed a global team of Master Black Belts

to deploy and continuously improve the design method.

Managed staffing, interfaced with customers and

supervised Reliability Engineers engaged in problem

solving, warranty prediction, and accelerated testing

for domestic, European, and Asian manufacturers.

. Deployed DFSS method globally across all business lines supporting $6B in

annual revenue.

. Generated $275M in new revenue from 3 large product programs launched as

a result of DFSS.

. Reduced development cycle time by approximately 35% due to fewer

build/test iterations.

. Improved First Time Quality >1( due to early analysis of noise

factors/interactions.

. Won project award at IQPC Six Sigma Summit 2007 in "Best DFSS Project"

category.

. Avoided > $9M in lifetime product costs using Reliability analysis

tools.

Michael S. Zwolinski

Page 2

DELPHI (continued)

Design for Six Sigma Master Black Belt (New product design) (2002 - 2006)

Introduced DFSS philosophy at Delphi to proactively apply the Six Sigma

methods to new product design. Performed extensive

benchmarking activities with training providers,

industry experts, customers and suppliers to select

the best methods for product innovation and

optimization. Established vision for DFSS program and

created curriculum to integrate tools into Delphi

development processes. Established certification

standards, coaching program and continuing education

forum. Managed linkage of DFSS with business unit

Technology Roadmaps to establish project selection

method.

. Established DFSS framework, class curriculum and training materials based

on a deep understanding of Six Sigma, Robust Engineering, Creativity

methods, Design of Experiment, Simulation tools, Balanced Scorecard,

Design for Reliability, Lean tools, and Toyota design methods.

. Conducted DFSS Champion and Black Belt training at global design centers

to ensure sponsor engagement as well as engineering expertise.

. Developed self sufficient program, which avoided consultant fees > $500K

per year and became corporate model for successful deployment.

. Provided extensive customer interface. Largest customer asked to buy our

DFSS curriculum.

. Personally spent more than 500 hours teaching the method in a classroom

setting.

Lean Six Sigma Master Black Belt (Continuous improvement & problem solving)

(2000 - 2009)

Coordinated first application of Six Sigma methods at Delphi through

certification with external consultant. Identified

project opportunities, and applied method to improve

products and generate savings. Integrated Six Sigma,

Lean and other problem solving skills into Delphi

Black Belt and Green Belt training programs.

. Identified opportunities and led projects resulting in $1.2 M in cost

savings

. Achieved Six Sigma Black Belt and Master Black Belt certifications based

on the DMAIC framework.

. Conducted Six Sigma Green Belt & Black Belt training, coaching,

certification and project selection for an advanced development staff of

300 people, generating over $10M in hard dollar cost savings.

Advanced Engineering Development Process Leader (1998 - 2000)

Represented division as corporate team member responsible for creating a

new product development process for the Delphi Corporation. Conducted

extensive benchmarking and team work to evaluate multiple needs, identify

best practices, and create a common template for all divisions of the

corporation while ensuring compliance with ISO-9001 design control

requirements.

. Developed Delphi New Product Development Process and Technology

Development Process based on Project Management principles, Stage-Gate

organization, and deliverables structure.

. Created process framework, deployed training globally and chaired gate

and design review sessions.

. Process deployed across product development for all business units

(combined revenue of $6B).

New Product/Process Specialist (1997 - 2000)

Managed a global cross functional team of electronics, materials, and

process designers to develop electronics on flex

circuit capability for automotive applications.

Formed extensive networks with others in the industry

to advance the technology.

. Leveraged resources by establishing a $1.5M research project funded by

the Singapore Government Economic Development Board.

. Partnered with IVF research labs, member companies, universities, and

supplier community to develop materials for bare die attachment to flex

circuit substrates.

. Optimized internal manufacturing processes resulting in $54M in new

product revenue, and 2 patents.

Michael S. Zwolinski

Page 3

GENERAL MOTORS CORPORATION, Warren, OH 1990 - 1997

Materials Development Engineer, Packard Electric Division

Managed internal development of conductive adhesive technology for cost

effective, environmentally friendly electronics

assembly. Established requirements and performance

benchmarks through leadership in industry consortia.

. Led $2M consortium project as Industry Champion for National Center for

Manufacturing Sciences cooperative research project including member

companies: AT&T, Ford, IBM, Hughes, United Technologies and Sandia

National Labs.

. Established & published industry standard test method for adhesive

materials.

EDUCATION

Master of Science, Materials Science & Engineering, Lehigh University,

Bethlehem, PA

Bachelor of Science, Electrical Engineering, Lehigh University, Bethlehem,

PA

CERTIFICATIONS

Reliability Engineer - American Society for Quality

Six Sigma Black Belt - American Society for Quality, Advanced Integrated

Technologies Group

Lean Six Sigma Master Black Belt - Air Academy Associates

Design for Six Sigma Master Black Belt - Air Academy Associates, American

Society for Quality

TRIZ Practitioner - Victor Fey Associates

Axiomatic Design - Dr Nam Suh

Associate Value Specialist - SAVE International

Minitab advanced user training - Minitab

PATENTS & PUBLICATIONS

US Patent # 5,891,367 Conductive epoxy adhesive

US Patent # 5,521,342 Switch with combined light pipe

"Best DFSS Project" award winner at IQPC Six Sigma Summit, Miami, Fl,

January 2007

Presenter - Developing your own DFSS Program, IQPC Six Sigma Summit, Miami,

FL, January 2006

Electrically Conductive Adhesives for Surface Mount Solder Replacement,

IEEE Transactions on Components, Packaging, and

Manufacturing Part C, vol. 19, pp. 241-250, Oct. 1996

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