Manager Quality Control

JOSEPH A. LEWIS

***** ********** **** ******** *******, CO 80908

719-***-**** ************@*****.***

PROFESSIONAL EXPERIENCE

Intel Corporation – Semiconductor Manufacturing (1993-2009)

Shutdown Team Leader for Emergency Response Team (ERT) and Total Chemical

Management (TCM) demolition team (2008-2009)

In this role I was responsible for the safety of all personnel onsite and the demolition schedule

of all gas and chemical lines. Site Incident Commander (IC) for any response that required

EMS or fire department assistance.

Met with contractors on a weekly basis to review standard safety protocols as well as

develop pre-task plans for unique demolition work that required confined space entry. There

were no serious (recordable) injuries to any Intel personnel during the project.

Successfully managed the TCM team, which was identified as the constraint of the

shutdown schedule at the beginning of the project. Using lean manufacturing applications to

work schedules and “buddy” system scheduling of work, the TCM constraint was never

realized. All work finished ahead of schedule allowing shutdown activities to progress

seamlessly and achieve all milestones as originally planned.

Developed a new business process for the Intel supply chain of vacuum pumps scheduled

for re-use at other factories. By defining customer-supplier relationships and each of their

needs, a new process was created which was 20% more efficient and ensured that pumps

arrived at their new destination.

Production Manager at Anadigics Inc, an Intel supplier, on special assignment working in

Warren, NJ (2008)

Consultant to executive staff and coach of newly hired production manager in areas of lean

manufacturing principles. Managed a team comprised of 25 Intel and Anadigics engineers and

equipment technicians to rapidly improve factory performance in the areas of;

Fab output – 58% increase from previous quarter. Results derived from lean manufacturing

practices as well as root cause resolution to chronic quality issues causing product fallout at

Test.

Cycle time reduction – 30% using 24hr run plans and coordination of maintenance activity.

Fab equipment downtime reduction - 55% through implementation of quality control

systems for equipment maintenance to sustain improvements as well as equipment vendor

re-negotiations. Improvement measured by equipment downtime reports run on a daily

basis.

Production Manager, Colorado Springs, CO (2006 – 2009)

As production manager, reporting to senior staff management, created and provided operational

direction to manage factory production line utilizing lean manufacturing principles. Aligned

organizational focus across all departments and implemented factory strategy across 168-hour

team. In this role, acted as the single point of contact for any activity that impacted

manufacturing.

Conduct daily operations meeting. State-of-the-factory report and current focus areas for

operations, process, maintenance and yield organizations. Enlist department managers to

resource and meet objectives.

JOSEPH A. LEWIS

Managed engineering process/yield improvement projects in conjunction with production

material to improve process control and maintain consistent production output.

Implemented inventory control system, that enabled factory cycle time reduction by more

than 55% while increasing output predictability and meeting all customer commitments.

Owned factory CT model and responsible for meeting factory output targets based on

desired throughput of the factory to its stated capacity. Influenced and stretched the

organization to achieve new milestones.

Managed construction schedules and resolved conflicts between semiconductor contractors

and internal teams of Intel personnel. Planned, scheduled, and made all tactical decisions

regarding construction impacts to fabrication facilities on the Colorado Springs campus.

Facilitated several radical increases in productivity and decreases in throughput time at

individual operations through the use of lean tools; Kaizen, TDLs, 5S and value stream

mapping. Results included 20% improvement in people efficiency, 80% decrease in

material throughput and an increase of 60% in defect detection.

Instructor for 2-day class “Supplier Introduction to Lean” to Intel suppliers on a

worldwide basis. Class included lean background, theory and hands on simulations.

Shift Manager, Colorado Springs, CO (2005)

Directly managed staff of 7 exempt operations managers (OMs) and 120 manufacturing

technicians (MTs) and co-managed the DRIM (Diffusion, RTA, Implant) process engineering

area composed of OMs, MTs, and Engineers across 5 shifts. Responsible for capacity, output,

and quality control of the area.

Managed shift team to multiple single-shift output records of defect-free material. Enabled

positioning of material on multiple product lines to meet customer commitments.

Supervised maintenance personnel to ensure timeliness of scheduled maintenance as well as

unscheduled equipment downtimes. Measured effectiveness of PMs using Mean Time to

Repair and Mean Time to Fail. Historical data was used a s baseline to improve

performance.

Responsible for the overall safety of all individuals working on the shift. Managed the shift

to an incident and injury free work environment with no serious (recordable or LDC)

injuries under my management.

Operations Manager, Albuquerque, NM & Colorado Springs, CO (1995-2005)

Managed groups of up to 45 technicians across all functional areas involved in wafer

production and wafer Sort area. Ensured technicians met safety, quality, and output objectives

on a shiftly basis. Managed technicians to consistently achieve shiftly and weekly goals.

Designed and drove equipment utilization project to increase capacity and re-allocate

equipment within the Intel network while supporting new technology, resulting in $4.5

million capital cost avoidance.

Site coordinator for Colorado Springs factory start-up, managing 300 technicians in CO,

NM and CA. Coordinated activities of remote-site training personnel, home-site training

personnel, and remote-site manufacturing managers. Ensured trainees on assignment

received the appropriate training enabling startup of Colorado Springs campus.

Incident commander (IC) for all shift ERT callouts. Conducted joint command training with

local Fire departments. IC in the Emergency Operations Center (EOC) during Y2K rollover.

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JOSEPH A. LEWIS

EDUCATION

Bachelor of Arts, Human Behavior

University of New Mexico, Albuquerque, NM

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