Six Sigma Manager

Craig A. Mayo

248-***-**** mobile . ****.*****@*****.***

Highlight of Qualifications

High potential Quality Professional with significant aerospace and

automotive engineering and manufacturing experience.

. Certified Lean Six Sigma Master Black Belt

. Certified QS9000 Lead Auditor

. Certified AS9100 Rev. C & ISO9001:2008 Internal Auditor

. Extensive product quality, manufacturing and operations expertise in

automotive and aerospace manufacturing.

. Supplier Technical Assistance (STA) with Ford Motor Company

responsible for all fastener systems on the Ford Probe and last

generation Mercury Cougar platforms.

. Responsible for leading Supplier Gold certification with Pratt &

Whitney for 2 sites. Improved scorecard metrics with Pratt & Whitney,

Rolls-Royce, and Snecma.

Work Experience

Production Pattern and Foundry, Carson City, NV Manufacturing Facility,

Oct. 2012 ~ Nov. 2012

Private Company; 120 employees; Automotive, Heavy Truck, Medical Device

industry

Sr. Process Engineer/Production Supervisor

. Hired to utilize Design of Experiments and other problem solving

techniques to identify key factors related to the production of

aluminum castings; specifically, to improve the mechanical properties

related to ductility of the metal.

. Initiated improvements and redesigned process that led to an 87%

improvement in conforming product.

. Improved tooling and reduced cycle time on CNC machine by 35.7%.

Firth Rixson Viking, Verdi, NV Manufacturing Facility, Aug. 2011 ~ May 2012

Private Company; 2,000 employees; aerospace industry

Manager, Continuous Improvement - Lean Six Sigma Master Black Belt

. Deployed Lean systems to complement our Theory of Constraints

operating system in the aerospace industry. Processes included

Forging, Precision Machining, Grinding, Heat Treat, NDT and

Administrative.

. Led Lean training (Root Cause Corrective Action, 5S, TPM, Standard

Work, Cells, SMED, Rapid Improvement Workshops, Kaizen Events) and

mentored Six Sigma Greenbelt projects.

. Led supplier root cause and corrective action training. Managed all

supplier and contractor root cause and corrective action activity.

. Led and mentored Engineering Dept. Project Excellence projects. These

resulted in improved forging designs that led to reduced machining

time, less rework, and reduction of scrap.

. Led process to attain Supplier Gold certification with Pratt &

Whitney, a rigorous lean program focused on elimination of all waste;

zero quality escapes for 12 consecutive months, minimum 95% on time

delivery, and documented evidence of cultural continuous improvement

activities.

. Led scorecard improvements with all major customers.

. Led all Continuous Improvement activities. On track to achieve more

than $3 million dollars cost savings for 2012.

Rio Tinto Minerals, Boron, CA Open Pit Mine and Refinery, Jan. 2009 ~ Apr.

2011

Public Company; 10,001 or more employees; mining & chemical processing

industry

Manager, Operational Excellence - Lean Six Sigma Black Belt

Master Black Belt for 880 person site, fully responsible for Lean Six Sigma

training of 12 Green Belts on site and another 36 from other Rio Tinto

Mineral sites. Mentored, coached and led projects in batch manufacturing,

continuous and transactional processes.

. As Champion for all Business Improvement projects at Boron achieved

more than $12 million hard dollar savings in 18 months on fertilizer,

boric acid and borosilicate glass products.

. Achieved 20% reductions in equipment and process downtime by executing

Designed Experiments and directing development of standardized work

practices. Train operators and chief operators new work procedures.

. Enabled off spec product to be reintroduced into our highest margin

product, saving cost to reprocess and increasing revenue $5.8MM

annually.

. Ran the Boric Acid back end operation for 5 months.

. Mentored project to harvest 3rd largest known Borate deposit (waste

evaporation ponds), extending LOM estimated 15 years.

. 5S Red Tag Event in the Truck Shop and Main Shop uncovered more than

$1.5MM in tools and parts, which led to a reduction in total

inventory.

. Led & mentored projects that extended life of haul truck tires and

reduced in transit packaging damage in rail fleet.

Federal-Mogul, Southfield, MI World Headquarters, Sep. 2007 ~ Oct. 2008

Public Company; 10,001 or more employees; automotive industry

Global Six Sigma Black Belt

Held full responsibility for leading global deployment of Six Sigma.

Championed combined Lean Six Sigma training program. Coordinated and

managed deployment of Six Sigma with an international team based out of

Asia, Europe, and the United States. Created all training materials and led

global deployment of Six Sigma for Powertrain, Aftermarket and Electrical

Divisions.

. Executed projects utilizing DMAIC methodology that resulted in

improved products and savings exceeding $2.5MM. Product lines included

bushings, bearings, coil steel, pistons and connecting rod assemblies,

and spark plugs.

. Led team responsible for complete redesign of Piston/Pin/Connecting

Rod assembly.

Developed working relationships with Caterpillar that led to multiple

contracts and awards for our Powertrain plants.

In recognition of project leadership I was given point-contact

responsibilities for all heavy equipment customers.

. Attained customer awards for more than 40 manufacturing locations

globally from heavy equipment customers. These awards led to new and

extended contracts.

Collins & Aikman, Southfield, MI World Headquarters, Jul. 2004 ~ Sep. 2007

Public Company; 10,001 or more employees; automotive industry

Manager, Warranty and Continuous Improvement (Nov. 2006 ~ Sept. 2007)

I designed the warranty improvement program for all domestic and

international automotive and heavy equipment customers for

Interior/Exterior Trim Systems to mitigate chargebacks and eliminate false

claims. I was promoted to Department Manager with additional Continuous

Improvement responsibilities.

. Built and executed cases that improved quality ratings with our major

customers in 2006.

. Personally executed 2 Six Sigma projects that achieved more than $4 MM

savings in 2006.

o Optimized Flexible Bright process eliminating warranty issues on

Radiator Grilles.

o Eliminated issue with material and redefined design standard for

all injection molded air outlets.

o Redesigned foam backing of Floor Carpet System.

o Led FIP/structural foam process improvements that reduced warranty

claims and costs 70%.

. Mentored and coached 25 Six Sigma Black Belt candidates to gain Master

Black Belt Certification.

. Created warranty process with Nissan that reduced their warranty costs

and netted a $1.7 million payback.

Senior Analyst, Warranty (July 2004 ~ Nov. 2006)

I designed and implemented the warranty reduction process for 15 C& A

manufacturing sites. With permission this was used as a benchmark by major

customers to train other suppliers. I created and facilitated all warranty

issue resolution teams.

. Warranty reduction initiatives resulted in savings of $6.7 MM in 2005

and $3.0 MM in 2006.

High degree of professional presence and customer interface skills. Very

adept at influencing to achieve results.

. I was instrumental for initiating our global Six Sigma training and

deployment program.

Guardian Automotive, Warren, MI Automotive Headquarters, Aug. 1998 ~ July

2004

Private Company; 10,001 or more employees; Automotive/Commercial-

Residential/Sports & Entertainment industries

Manager, Reliability Engineering (Feb. 2004 ~ July 2004)

Established reliability engineering function within Guardian Automotive.

. Sponsored team that realized an early design improvement resulting in

the elimination of a mechanical stress issue on liftgate glass that

could have exceeded $8 MM in warranty costs annually.

Manager, Warranty Engineering (Dec. 1999 ~ Feb. 2004)

Responsible for staff of 5 professional direct reports and 32 hourly

indirect reports.

. Directed team resulting in rapid part redesign and process

improvements for a tempered glass encapsulation issue netting a

warranty cost reduction in excess of $1.2 MM.

. Developed glass warranty process with major customer to identify non-

warranty field failures. Savings exceeded $12 MM from prior year with

a higher sales volume. Customer asked me to manage all glass warranty

claims nationwide as a result of this program.

. Developed warranty cost reduction activities with customers to realize

more than $12 MM savings in MY 2003. Savings achieved through

increased accuracy of claims reporting, improved materials

specifications, and faster field response programs generated by my

office.

. Achieved warranty payment from major customer in 2002 for

improvements leading to reduced warranty costs.

. Reduced Guardian warranty cost exposure to zero with major customer

for 2003 from prior year payment exceeding $2MM.

Passed first TS-16949 audit with zero non conformities.

Engineer, Supplier Quality Assurance and Warranty (Aug. 1998 ~ Dec. 1999)

Directed and developed Corporate Supplier Quality and Warranty functions.

Managed quality for 1k2k paint, anodized, and powder coat process issues at

customer locations.

Developed warranty tracking and reduction system.

Redesigned components during launch of SW-164 program to avoid launch

delays.

Responsible for managing all purchased product and ensuring on time new

product launch.

Wrote business plan to create Warranty Department. This led to my promotion

to Department Manager.

Ford Motor Company/Mazda Motors, Flat Rock, MI Assembly Operations, Jan.

1987 ~ July 1998

Public Company; 10,001 or more employees; automotive industry

Engineer, Supplier Quality Assurance (July 1997 ~ July 1998)

Located at Mazda/Ford Joint Venture in Flat Rock, Michigan.

Proactively developed local source supply base for threaded fasteners,

ensuring compliance with AIAG and ISO standards. Utilize FMEA, Risk

analysis, PDPC, and other tools.

. Champion resolution of part and assembly issues utilizing Statistical

Process Control, 8D methodology, Ishikawa diagrams, Pareto charts,

Scatter diagrams, ANOVA, and other tools.

Senior Staff Member, Supplier Quality Assurance (Jan. 1991 ~ July 1997)

Approve new model parts through testing and dimensional analysis.

Perform mechanical, chemical, environmental, and metallurgical testing of

components and materials.

Experienced with photomicrography. Certified sheet metal for Stamping and

Body Assembly operations.

. Liaison as manufacturing engineer supporting Final Assembly

Operations.

Staff Member, Quality Control (Jan. 1987 ~ Jan. 1991)

. Environmental and dimensional analysis of interior and exterior trim

components.

. Performed warranty analysis of components and materials.

. Designed and fabricated test jigs and fixtures.

. Developed and managed lab budget and checkbook system.

Lectron Products, Rochester, MI, Aug. 1981 ~ Dec. 1986

. Attended college and training seminars while working as electronic

technician for an electrical and electro-mechanical auto part

supplier. Began working with SPC and Lean manufacturing.

Education & Certifications

Cleary University, Ann Arbor, MI, BBA, Major in Quality Management August

2010

Firth Rixson, Verdi, Nevada, AS 9100 Rev, C Internal Auditor March 2012

Rio Tinto, Boron, California, ISO 9001:2008 Internal Auditor Certification

October 2010

IQF, Tucson, Arizona, Lean Six Sigma Master Black Belt Certification

December 2009

Caterpillar University/George Group, Peoria, Illinois, Six Sigma Black Belt

August 2008

IQF, Tucson, Arizona, Six Sigma Master Black Belt Certification February

2008

Caterpillar University, Peoria, Illinois, Six Sigma Deployment Champion

Certification October 2007

IQF, Tucson, Arizona, Six Sigma Black Belt Certification December 2006

ANSI/RAB, Dearborn, Michigan, QS-9000 Lead Auditor Certification April 1999

Professional Memberships

Organizer/Chair: Society of Automotive Engineers 2007/2008 World Congress

Lean and Six Sigma Technical Sessions

Organizer/Volunteer: Meadowbrook Hall Concours d'Elegance

Professional Memberships: International Quality Federation, American

Society for Quality, Society of Manufacturing Engineers, Lean Enterprise

Institute, Society of Automotive Engineers

Contact this candidate