Engineer Six Sigma

James E. Herbener

**** ********* ****, *********, ** 28226 704-***-**** abnuxg@r.postjobfree.com

MANUFACTURING ENGINEER\MANAGEMENT CONSULTANT PROFILE

SR.

Over 20 years of Engineering and Management Consulting Experience in Manufacturing

and Service Organizations Managed Multiple High-Profile Projects to Successful Results

Earned Multiple Awards for Outstanding Performance

Accomplished, outcome driven consultant with year-over-year success in leading challenging

initiatives, with emphasis on problem solving, strategic planning, process development, product

design, engineering, quality assurance, project development, capital improvement, application

development, and technology integration. Fully computer literate, including Windows OS, MS

Office as well as proprietary applications. Ability to quickly learn new software. Available for travel.

CORE SKILL AREAS

Strategic Operational Planning & Execution; Solutions Analysis & Implementation; Six Sigma &

Lean Methodologies in Manufacturing and Service Environments, High-Tech Production and

Maintenance Operations; Process Analysis, Evaluation & Troubleshooting; IT Application

Development and Integration.

PROFESSIONAL EXPERIENCE

EQUIFIRST CORPORATION – Div. Barclays Capital – Charlotte, NC 2005-2009

Financial Services

Sr. Process Improvement Consultant

Support business process reengineering, process design, performance metric establishment,

realignment initiatives, and cost reduction\avoidance programs that consistently improve product

output and quality. Report to SVP Operations.

• Lead JAD sessions with Business and IT personnel to validate new processes and technology

integration effort in retail loan operation. Wrote business requirements for Point of Sale

software platform, supported justification of final selection and integration of application into

startup operation.

• Managed 17 major departmental reviews and IT projects recommending and implementing

process change and supporting technology initiatives representing over $5 million in annualized

cost savings and\or avoidance. Prepared Process Maps to document As-Is processes.

• Conducted research on Electronic Content Management and Business Process Management

technologies with the intent of automating business processes and converting the mortgage

fulfillment process to a paperless one with an annualized cost saving opportunity in excess of

$2.8 million (355% ROI). Initiated and managed pilot paperless loan project to better

understand impact to business processes.

• Created loan file image transfer process to 3rd party clients, saving EquiFirst $350,000 in annual

file mailing costs.

• Conducted analysis for the CFO to determine which mortgage operations could be out-sourced

or off-shored.

• Prepared Value Stream maps (iGrafx) contributing to reduction in steps required to validate loan

setups and 10 FTE reduction in resources required.

• Developed and delivered employee suggestion program using MS Excel\Outlook VBA

automation to solicit continuous improvement ideas from associates that had a 20% acceptance

rate;

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• Developed and Administered Capacity Planning System application using Excel\Access VBA

Automation to monitor and forecast resource requirements.

• Created Client Server applications for Appraisal Services and Vendor Approval using MS Access

in a multi-user, shared environment. Applications contained interoperability functionality with

Excel and Outlook.

• Implemented barcode technology in operations pipeline to streamline handling of loan folders.

BANK OF AMERICA – Charlotte, NC 2002-2004

Financial Services

Business\Systems Integration Consultant

Support Compensation Group’s Year-End Compensation Delivery Business Process and Supporting

Technology. Report to Sr. Service Delivery Manager.

• Worked with Fidelity to develop business requirements for enterprise rollout of Fidelity

Compensation Planner. Provided leadership in development of business process, GUI design,

report, analytics, and data for To-Be processes.

• Prepared Data Conversion Strategy for domestic and international (Europe, Asia, Latin America)

rollout of Fidelity Compensation Planner.

• Completed Bank of America DFSS training course. Participated in Six Sigma DFSS Project

projected to save Bank of America over $100K+ while improving associate retention through

Pay for Performance.

• Responsible for gathering business requirements, maintaining data quality, report development,

creating ad-hoc queries and user acceptance test scripts and resolving problems with third-party

vendor (Exult) for As-Is process.

• Developed a number of MS Office (Word, Access, Excel, Outlook) desktop applications in

support of Compensation department project initiatives such as Single Salary Review, Range

creation, 2004 and 2005 Target Setting Process and Year-End recommendation collection.

Prepared training documentation and conducted training sessions.

IT Contractor – Charlotte, NC 2001

• COMPASS GROUP – developed and released for production Windows NT desktop application

utilizing Visual Basic 6\Windows API to control asynchronous execution of third-party

ISP\VPN\FTP applications with client feedback (Apex Systems Contract).

• ENOVIA CORPORATION – created Excel VBA application to convert text data file to a

series of charts for customer review with automated customization (Robert Half Contract).

SPICER OFF-HIGHWAY DIV., DANA CORPORATION – Statesville, NC 1995 – 2000

Manufacturing

Sales Engineer 1998 - 2000

Responsible for transmission product sales in excess of $30 million annually, as well as forecasting

and market reconnaissance supporting 25 diverse clients in the off-highway vehicle market.

Design Engineer 1995 - 1998

Designed, developed, and coordinated testing of new transmission and torque converter variants for off-

highway vehicle market utilizing 3-D Pro-Engineer CAD software. Reduced manufacturing cost through

participation in Design for Manufacturability reviews, FMEA reviews and Kaizen Blitz process

improvement teams.

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CATERPILLAR, INC. – York, PA 1989 – 1995

Manufacturing

Sr. Manufacturing Engineer

Lead engineer responsible for all engineering activities related to implementing Lean manufacturing

processes, machine cells, tooling, and material handling equipment to reduce cost, improve quality

and increase responsiveness of the Precision Hydraulics “Focus Factory” Commodity in 1.5M sq. ft.

facility.

• Successfully installed $5.5 million CNC Multi-Spindle Turning Center and Computerized

Inspection area to produce small precision turned components, reducing setup times to less than

10 minutes and allowing Kanban pull system to be implemented, reducing historical inventory

levels.

• Developed program, process documentation and tooling for over 200 parts machined on Star

CMC-32 Swiss-type 6-axis turning centers.

• Trained and managed replacement employees during protracted UAW strike and improved

machining efficiency from 55% to over 90% while exceeding production targets.

GENERAL DYNAMICS LAND SYSTEMS DIVISION – Scranton, PA 1986 –1989

Manufacturing

Project Engineer

Responsible for financial analysis, justification and management of $20+ million in capital

improvement projects for U.S. Army Defense Contractor at 220,000 sq. ft manufacturing facility

producing parts for the M1A1 main battle tank.

• Developed Statistical Process Control program\database to collect data on critical part

characteristics to produce control charts and calculate Cpk for variation control and analysis.

EDUCATION & ACTIVITIES

BACHELOR OF SCIENCE, MECHANICAL ENGINEERING: Lehigh University, Bethlehem, PA

MASTERS IN BUSINESS ADMINISTRATION, FINANCE: Lehigh University, Bethlehem, PA

PROFESSIONAL DEVELOPMENT: 6 credits, Penn State University MS Mechanical Eng. 4.0 GPA,

Problem Solving Techniques - Kepner-Tregoe, Inc.; DFSS Training – Bank of America; Six Sigma

Training – Dana Corporation (ASQ), Bank of America; Kaizen Methods Training – Dana

Corporation; TQM & Toyota Production System (Lean) Training- Caterpillar

HONORS & AWARDS: Award of Excellence Winner (2007); Leadership Award (2003, 2004)

PROFESSIONAL AFFILIATIONS: American Society for Quality (ASQ)

CERTIFICATIONS: Six Sigma Green Belt – ASQ – Expected 2009

SOFTWARE: Database and Data Management (SQL, Access), Flowcharting (Visio, iGrafx),

Modeling and Optimization (Excel Solver), Presentation (PowerPoint), Programming (VB.Net, VBA,

COM, Windows API), Project Management (MS Project), Word Processing (MS Word, Adobe),

Communication (Outlook VBA), Simulation (iGrafx, Arena), Spreadsheets (MS Excel), Statistical

(Minitab 14, Excel), Document Management (EMC Application Xtender)

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