Manager Six Sigma

ERNIE KONKOLI

* ********* **** *****: 336-***-****

Avon, CT 06001 E-Mail: ************@***.***

Metrics-Driven Lean/Six Sigma Manufacturing Leader

Dynamic manufacturing leader who builds winning teams in competitive markets by executing strategic

and tactical plans, developing strong leadership teams and empowering high-involvement workforces to

achieve customer satisfaction using Lean Manufacturing, Six Sigma, TPM and Root Cause Analysis.

* 36% to 98% OTD in 18 Mos: In a meeting with an Air Force General, the President of Manufacturing for a

Fortune 100 aerospace company thanked me for “the most successful turnaround in the company s history”.

* Lean & Six Sigma: Completely transformed a 475 employee, 240,000 ft business into a Lean/Six Sigma

enterprise. The employees signed a poster in the factory calling me “the wind beneath their wings”.

* 31% productivity increase & record safety levels: The owner of a privately held company literally danced on

the roof when we achieved record performance levels at his 35 year old facility.

* Received corporate Leadership Award for work to restructure my business around Best Practices.

Lean Manufacturing Six Sigma/SPC Continuous Improvement

Kaizen Teaming Root Cause Analysis High Involvement Teams

Quality Assurance Capital Investments Project Management

Supply Chain Mgmt Total Productive Mtce New Product Development

Strategic Goal Deployment Company Turnarounds Plant Design & Startup

PROFESSIONAL EXPERIENCE

EASTERN PLASTICS, Inc., (EPI) Bristol, CT 5/2007 - 12/ 2008

Full P&L for $32M unit of IDEX Corporation specializing in the manufacture of precision machined

components and assemblies for the medical diagnostic and analytical instrument markets.

GENERAL MANAGER

$30M 3-Year contract negotiated with major medical instrument OEM.

Restored key customer relationships to add $3.5M/yr sales growth opportunities.

Developed leadership team & upgraded shop control systems to support rapid sales growth.

30% increase in throughput of constrained product lines through Lean Manufacturing methods.

Used Value Stream Mapping to reorganize entire office and streamline transactional processes.

Championed ten Kaizen teams to create Lean cells and establish kanban pull systems.

ADVANCED TURBINE COMPONENTS, Inc., (ATC) Winston-Salem, NC 2001 - 2006

Full P&L for $42M producer of critical forged and machined components for power gen turbines and

aero-engine products.

2004 – 2006

VICE-PRESIDENT & GENERAL MANAGER

DIRECTOR OF OPERATIONS 2001 - 2004

$8M sales won from China and Japan with marketing and new product development plans.

$10M order for aerospace products secured with an aggressive sales strategy supported by

strategic capital upgrades and attaining AS-9100 and NADCAP aerospace certifications.

$1.3M reduction in labor, supply and service costs by introducing contract labor, negotiating new

vendor agreements and developing in-house support services.

Developed and kicked off company-wide Lean Manufacturing process prior to company sale.

ERNIE KONKOLI

Phone: 336-***-**** ************@***.***

LEIGH FIBERS, Inc., Spartanburg, SC 1994 - 2001

$110M leading textile and fiber by-products company. After 30 years at this location, productivity had

stagnated and costs were climbing causing serious profit erosion. Recruited by third generation owners to

introduce Lean and Six Sigma process improvement programs and to lead investments in new processing

technologies.

VICE-PRESIDENT, MANUFACTURING

Reduced staffing from over 400 to 315 employees due to significant overall performance

improvements from creating a continuous improvement culture.

30.8% increase in manufacturing labor productivity by introducing new technologies, effective Total

Productive Maintenance and Root Cause Analysis programs creating increased equipment up-time.

21.3% reduction in average unit costs by converting low-skilled jobs to contract labor and consolidating

supply chain from over 60 key suppliers to 18 supplier partners. Added more than $5M to EBIT/Year.

99% OTD with 99.5% quality conformance rates were maintained routinely.

79.6% reduction in workers compensation costs (One lost time case in last 5 years) after creation of industry

model safety & health program.

PRATT & WHITNEY AIRCRAFT ENGINES (PWA), Columbus, GA 9/1988 - 1994

This new highly automated operation for aircraft engine components was losing over $10M/year and was

more than six months overdue to customer requirements. Recruited to lead what was described by the

Division President as “the most successful turnaround in Pratt & Whitney history”.

MANAGER OF MFG AND DEVELOPMENT OPERATIONS (Business Area Manager)

Managed 475 employees including a team of eight functional and business unit managers.

Grew manufacturing output to $100M from $40M in five years.

98%+ on-time delivery performance up from 36% within first 18 months.

Worked with the creators of the Toyota Production System (Lean) to redesign factory into four

fully integrated product family flow lines.

70.3% reduction in unit costs; 82.7% reduction in scrap by creating model Six Sigma/SPC

program. Point-Of-Origin-Process-Control program won company-wide award.

17 inventory turns (from 3.25 in 1988) after Lean transformation by streamlining product flows.

Reduced process lead times from 16 weeks to three weeks moving to a Make-to-Order operation.

1/1988 – 9/1988

ONTARIO UK LTD., Wales, United Kingdom

Recruited to lead troubled $20M privately held precision forging facility for prosthetics and aero-engine

parts. Company was losing over $150K/month due to currency rate and inefficient plant operations.

OPERATIONS MANAGER

$8M/yr new UK sales developed with major aerospace OEM.

81% increase in sales per employee through SMED and JIT methods.

42% reduction in inventories and 30% reduction in lead-times.

$126K/mo positive cash flow from ($150K)/mo within 7 months.

Negotiated the company s first no increase agreement with British Steelworkers union.

EDUCATION

MBA, Baldwin Wallace College, Ohio, 3.9/4.0 GPA

BS Mfg Eng, Kent State University, Ohio, 3.7/4.0 GPA (Magna Cum Laude)

Lean Expert Trained by Shingijutsu Company Consultants

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