Manager Quality Assurance

TJ Forsyth

Email: *********@********.***

Address: *** ****** ****

City: San Clemente

State: CA

Zip: 92672

Country: USA

Phone: 949-***-****

Skill Level: Director

Salary Range: $150,000

Primary Skills/Experience:

See Resume

Educational Background:

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Job History / Details:

TJ FORSYTH

San Clemente, CA 92672 949-***-**** (C)

**********@***.***

OPERATIONS PROFESSIONAL

Accomplished C.P.I.M. certified operations professional with proven record of success in providing leadership in all facets of production and operations within the pharmaceutical/medical device arena. Ability to improve efficiency, improve quality and decrease costs. Key competencies include:

* Lean Manufacturing / Supply Chain * Strategic Manufacturing Planning

* Product Development / Introduction * Budgeting / Cost Control

* Process / Product Innovation * Process Capacity Expansion

* Risk Analysis / Mitigation * Leadership / Team Collaboration

EXPERIENCE

ALCON LABORATORIES, Ft. Worth, TX 1987-2012

Associate Director, Operations, Irvine, CA (2011-2012)

Oversaw/directed overall surveillance and operations success of Consumables and Laser probe production areas responsible for manufactured product valued at $60M+ annual cost.

* Had direct responsibility for six professionals and indirect responsibility for 105 nonexempt direct labor, providing motivation and support to career development and technical expertise.

* Proactive measurement and process surveillance that promoted positive safety culture.

* Achieved product cost reduction in laser probe manufacturing in excess of $ 500,000 annually from 2009 to 2012 by:

- Integration of laser probe/consumables manufacturing processes using lean techniques

- Manufacturing process redesign for laser probe assembly

* Increased laser probe output rate by more than 200 % by:

- Guiding engineering staff in identification, installation validation and startup of

automated sheath fiber insertion system

- Facilitated product re-design to remove redundant part

- Supported transition from canned air to compressed air for cleaning components

Manufacturing Production Manager-Consumables (2001-2011)

Managed all manufacturing, engineering, purchasing and planning functions in support of items manufactured in a controlled environment requiring subsequent sterilization.

* Developed and implemented operating plans that included financial objectives, sales and production plans, inventory levels, process improvement, asset utilization, capital and expense budgets and other plans as required that achieved division objectives.

* Managed concurrent support of product/process design of all new product introductions.

* Managed regulatory compliance, quality assurance, and provided audit support.

* Managed cleanroom, warehouse, material handling and distribution functions.

* Managed, counseled, trained and developed nine professionals with indirect responsibility for 50 nonexempt direct labor.

* Increased Consumables manufacturing capacity from 10,000 units per month to 120,000 with no increase to direct labor needs or cleanroom space.

* Fostered volume growth to 1.5M+ units per year by leading all sourcing aspects of new product introduction and on-going production support.

TJ Forsyth - 949-***-**** Page 2

ALCON LABORATORIES (cont.)

* Achieved $ 11M reduction in annual product costs by:

- Managing manufacturing outsourcing of tubing sets and small parts assemblies included in

surgical procedure packs, including supplier selection and validation of maquiladora

- Initiating/leading team to convert supply of completed packs to the custom pack

factories from sterile product pulled from inventory to non-sterile versions built to

order, avoiding unnecessary sterilization and freight costs and reducing finished goods

inventory required to support the custom pack plants

- Facilitating development of delivery system for just-in-time receipt of cassettes

- Revamping labeling process to incorporate use of automated print and apply system

- Negotiating, validating and implementing anterior pak stacking change

- Developing backflush system for reducing transaction requirements

- Organized and guided cross-functional team in development of sterilization pallet

reconfiguration to optimize use of chamber

Operations Product Manager-PCB/Cable (1994-2001)

Managed all manufacturing, engineering, purchasing and planning functions in support of printed circuit board and cable assemblies used in equipment manufactured at the Irvine, CA facility.

* Provided concurrent support of product/process design of all new product introductions.

* Developed and managed annual volume, expense and capital budgets.

* Increased capacity by 70% and reduced labor costs by in excess of $ 300,000 on an annual basis by:

- Identification/implementation/validation of a $ 500,000 surface mount technology line

expansion

- Implementation of a point-of-use component stocking process utilizing dock to stock and

kanban pull systems with vertical storage units for on line storage of components and test

equipment

- Initiating/leading/managing the manufacturing outsourcing of cable assemblies

* Reduced product cost in excess of 10% per year.

Manager, Planning and Inventory Management (1989-1994)

Senior Planner (1987-1989)

EDUCATION

MBA, Pepperdine University, Malibu, CA

BA, Business Administration/Operations, California State University, Fullerton, CA

CERTIFICATIONS

Certified Production and Inventory Management (Association for Operations Management (A.P.I.C.S.))

Medical Product Development (UCI)

PROFESSIONAL MEMBERSHIPS

Association for Operations Management (A.P.I.C.S.)

American Society for Quality (ASQ)

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