Customer Service Medical Device

DOUGLAS R. KORFE

**** ********** ** 325-***-****

Grand Prairie, TX 75054 ****.*****@*****.***

Summary

A proven leader with the ability to analyze complex situations and develop creative solutions in demanding environments. Recognized for improving processes and turnarounds. Extensive experience in management, operations, training, and safety with an emphasis in Lean Manufacturing. Specialties include Kaizen, JIT, 5S, TPM, OEE, ME2, SMED.

Experience

Sterigenics International: (Medical Device & Diagnostics – Sterilization) Grand Prairie, Texas 2011 - 2013

General Manager

Responsible for all quality, regulatory, financial, and customer service metrics for the plant.

• Improved quality metrics by 45%, including reductions in Deviations (89%), Damages (63%), NCR’s (30%), Customer Complaints (74%), and Reprocesses (53%).

• Added new Sterilization Chamber - increased plant capacity by 20% without increasing headcount.

• Reduced the number of open CAPAs from 76 to 17, reduced number of aging CAPAs from 47 to 1.

• Drove PM compliance to 100%.

• Led various EH&S initiatives to improve safety in facility.

o Implemented a 5S program for facility.

o Equipment Specific LOTO Program.

o Achieved 91% reduction in Equipment Alarms.

o Improved warehouse air quality and delivered $1MM Cost Avoidance by working with customer.

• Reduced Cycle Time by 45% by streamlining process flow.

Cardiovascular Systems Inc: (Medical Device & Diagnostics – Orbital Atherectomy) Pearland, Texas 2011

Plant Manager

Responsible for all quality, regulatory, financial, and customer service metrics for the plant.

• Launched Continuous Improvement Program. Mentored 9 Kaizens resulting in >$10k/yr waste reductions.

• Led Shaft RM improvement initiative resulting in $35k/yr in material savings.

• Developed a 5 year staffing and layout strategy for facility.

• Established Shaft Laser Welding, Pump Assembly, and FG shipping processes, ahead of schedule.

Ethicon: (Medical Device & Diagnostics - Sutures) San Angelo, Texas 2000 – 2011

Process Excellence Manager (2009 – 2011)

Drove continuous improvement initiatives throughout the extended suture value stream. Tools included Training, Kaizen, Benchmarking, Project, Suggestion Program, and Plant Strategy/Business Planning Activities. Coordinate plant project activities.

• Delivered $1.3MM CIP Project. Reduced DL HC by 27% in Machine Shop.

• Achieved Plant Lean Maturity Assessment Level of “Pull”.

• Developed 2010 San Angelo PE Deployment Strategy.

• Completed Lean Recertification Project resulting in a $54k/yr waste savings.

Operations Process Leader – Sterilization/Final Processing (2008 – 2009)

Responsible for achieving output, safety, efficiency, quality, people, and process excellence metrics. Developed business plan.

• Managed 189 Associates and 4 Departments.

• % HC Reductions – Final Processing (14%), Salary (22%), Sterilization Wage (52%).

• Increased weekly suture packaging outputs by 17%.

• Increased Credo score by double digits in 2 consecutive years.

DOUGLAS R. KORFE PAGE 2

Operations Process Leader – Cordis/Sterilization (2006 – 2008)

Responsible for achieving output, safety, efficiency, quality, people and process excellence metrics. Developed business plan. Served as liaison between Cordis and Ethicon, San Angelo facilities.

• Executed a Lean Black Belt Certification project resulting in $1.5MM/year savings to Cordis

• Completed a Lean Green Belt Recertification project resulting in $373,000/year savings to Cordis.

Operations Process Leader – Needles/D-Specials (2005 – 2006)

Responsible for achieving output, safety, efficiency, quality, people and process excellence metrics. Developed business plan.

• Achieved Green Belt Certification (Lean) resulting in efficiency gains of $255,000/yr for D-Specials suture dept.

• Served key planner in suture Asset Reconfiguration Projects.

San Angelo Site Lead – Project Athens (2004 – 2005)

Responsible for coordination of equipment, process materials, and validation materials for movement between suture manufacturing sites. Developed new processes for receipt of goods. Craft/Wage training. Label Copy changes. Communicated with a multi-facility project team.

• Established Juarez Repack Department.

• Refurbished and shipped 63 pieces of equipment in conjunction with project timelines.

• Utilized Lean Processes to improve Repack Department efficiency and product efficacy.

• Established tracking tools to improve flow of process raw materials.

• Coordinated label copy changes for 20 RMC’s to read “Assembled in Mexico”.

• Achieved $5.8MM in Annualized Cost Savings.

• Achieved Financial and Quality Targets.

Engineer/Facilitator (2000 – 2004)

Served as direct line supervisor of all Automated Suture Attachment and Foil Packaging departments. Lead Facilitator (2002 – 2004), responsible for coordination of activities across 4 groups (Training, OEE, Projects, Efficiency Initiatives, Quality, & Safety). Departments accounted for 55% of plant Attachment (>115,000 Dz/Wk), and 100% plant Foil Volume (>220,000Dz/Wk).

• Validated manual swaging codes into automated processes, resulting in a 12 headcount reduction in wage positions.

• Served as Sutures CPAS Champion, achieving 100% closure rate and reducing open CPAS’s by 67%

Mobil: (Natural Gas Exploration and Production) Liberal, Kansas 1998 - 2000

Facilities Engineer

Responsible for management of engineering projects for above-ground facilities in the Hugoton field.

• Refurbished (4) and developed (1) salt water disposal site

• Produced P&ID drawings for 7 compressor stations and 22 salt water disposal sites.

• Reduced Mobil expenses by $250,000/yr through the evaluation and reduction of wellhead compression rental fleet.

• Identified origins of Iron Sulfide in the gas gathering system through simple and innovative data gathering solutions.

Education

B.S. (Mechanical Engineering) New Mexico State University, Las Cruces, NM - 1998

Certifications

OSHA 30 – September 2012

Lean Black Belt – January 2009

Lean Green Belt – August 2006

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