JOSEPH A. ABBAS

915-***-**** ac32og@r.postjobfree.com

EXECUTIVE PROFILE

OPERATIONAL EXCELLENCE & LEAN OPTIMIZATION, LSSMBB, PMP Toyota Production System Six Sigma DMAIC Rapid Continuous Improvement Kaizen Strategy DYNAMIC CHANGE LEADER driven by high standard work ethics and unwavering commitment to operational excellence. Analytical and business savvy lean operations strategist, project manager, and master black belt. Demonstrated leadership skills in building strong partner relationships with customers, suppliers, and internal development teams. Growth oriented with profound knowledge of industrial production systems, value chain, lean enterprise, six sigma methodology, and project management techniques at a global scale. Empowering leader able to drive kaizen teams to achieve objectives and meet critical deadlines. Areas of Expertise

Industrial Engineering

Strategy Deployment

Gemba Leadership

Lean Manufacturing

DMAIC Methodology

Kanban Pull System

Process Flow Control

Value Stream Mapping

Kaizen Leadership

Quality Management Sys

Quality Assurance

APQP/PPAP/FMEA

Project Management

Train The Trainer

P&L Management

PROFESSIONAL SUMMARY

GLOBAL RESOURCES, Chicago, IL (2015 – Present)

SR LEAN CONSULTANT

Consult with small to medium size businesses to provide solutions in the areas of strategy, lean supply chain operations, lean manufacturing and continuous improvement in various industries; business turnaround specialist, with effective lean leadership and creative thinking.

Restructured operations and implemented lean initiatives for over ~$800M; realized cost reductions and cost savings for over $63M, in areas of manufacturing, service, and distribution.

Trained executive teams, quality, maintenance, and operations management teams on lean manufacturing principles, value practices, Kanban systems, and kaizen leadership tools & techniques.

Kaizen Promotion leading lean manufacturing efforts and quality improvements through the use of the Kaizen philosophy to attain improvement objectives as productivity improvement, customer satisfaction, workforce development, defect reduction, and new product development.

Developed Company’s lean strategy, metrics, standardization and A3 process deployment.

Coordinated cross functional resources, facilitated events and mentored functional lean leaders.

Budget, Standard Work, Model Line, 5 S, Safety, Pull Kanban Systems, Develop team members. Intimate knowledge and experience with TPS (Toyota Production System) deployment.

Strong leadership and teamwork skills and a demonstrated ability to drive to consensus and lead teams to successful outcomes via influence and motivation.

Coordinated with General Managers to identify improvement opportunities and define Kaizen events.

Implemented DMAIC methodology, practices and techniques to ensure the most lean flow and economical movement of materials through the supply chain to achieve cost-effective logistics practices and inventory levels while meeting customer delivery requirements. JOSEPH A. ABBAS 915-***-**** ac32og@r.postjobfree.com 2 WEIR OIL & GAS, Fort Worth, TX (2012 – 2015)

LEAN OPERATIONS Sr MANAGER

Optimized supply chain operations & established a vendor quality dept. (~$350M); (6) direct reports.

Designed & implemented – for five plants - a closed loop visual & electronic Kanban pull system for over 2000 part numbers sourced from ~35 strategic suppliers

Organized and led over 75 kaizen in areas of capacity planning, 5S program, kanban systems, lot-trace serialization, first article, supplier quality, incoming inspection, process flow, and safety management.

Conducted supplier business reviews with strategic suppliers that include supplier performance reviews, technology roadmaps, business growth strategies and supply market changes.

Streamlined production control planning on a continuing basis through improved equipment reliability, operator development, and material availability, which reduced manufacturing lead-time by 20%.

Analyzed data, including enterprise requirements planning information and prepared consolidated managerial reports as needed to facilitate optimal supply chain execution.

Led the implementation of lean operation tools including pull systems and visual management systems in the distribution center

Select Achievements:

Reduced inventory cost by ~$21M by implementing a capacity management process and through resizing raw material and purchased components inventory levels needed on hand.

Realized an operational cost reduction of ~$2.5M by reducing acquisition time, storage space, and production flow. Eliminated the use of an off-site warehouse and implemented a supplier-plant direct pull delivery.

Researched and determined status of unreceived and damaged materials and created system to help track future claims and carriers obligations, which resulted in initial savings of $184,000 annually DISH NETWORK, El Paso, TX (2007 – 2012)

PLANT OPERATIONS Sr MANAGER

Managed reversed logistics operations (~$300M) and QA department (12 direct reports, ~350 indirect).

Managed the tactical and strategic functions of the supply chain logistics operations, including procurement, vendor selection, vendor audit, order management, warehousing and logistics.

Designed & implemented a comprehensive quality assurance program for the Dish organization; including supplier evaluation, receiving inspection, quality control, product testing, and manufacturing quality.

Provided on-going support for modification and de-bugging of manufacturing and material handling automation equipment, resulting in a major reduction in down time.

Drove contract negotiations across multiple types of service providers: transportation, professional services, technology, warehousing & logistics services.

Analyzed factory returns, conferred work personnel and actual customers to determine sources of problems and acceptable refurbishing standards, resulting in 35% reduction in new material cost Select Achievements:

Achieved a cost reduction of ~$2.34M per year by redesigning the acquisition process and production flow of field returned equipment.

Remodeled warehouse facility from infrastructure, layout, stock segmentation, flow, and equipment; resulted in improving safety conditions, inventory accuracy, and increased plant throughput by ~50%.

JOSEPH A. ABBAS 915-***-**** ac32og@r.postjobfree.com 3 VALEO MOTORS, Juarez, MX (2002 – 2007)

LEAN CHAIN OPERATIONS MANAGER

Managed a supply chain (~$45M) in a Maquiladora environment under NAFTA regulations. Managed and directed supply chain personnel (6 direct; 129 indirect) in key Supply Chain functions such as materials planning, scheduling and ordering activities associated with the delivery of specific customer motors & actuators, direct and indirect material purchasing, receipt, disbursement, and warehousing.

Directed a team to drive lean supply chain performance from customer demand to order delivery. Managed entire supply network flow, procurement activities including MROs, 3rd party logistics, and customs office.

Defined and refined Company’s procurement vision, strategy and execution plan at multiple sites, securing buy-in from and developing effective relationships with senior leadership and other key stakeholders throughout the Company.

Select Achievements:

Implemented a materials control process, which reduced cost of freight from ~$600K to ~$50K per month, and eliminated the use of an offsite warehouse with a yearly cost of $140K.

Reduced inventory cost by ~$1.5M through negotiations with ~22 Asian suppliers. Established a local point of supply and release by standard pull quantity across USA-Mexican borders. YAZAKI USA, El Paso, TX (1996 – 2002)

NEW PRODUCT INTRODUCTION PROGRAMS MANAGER

Directed ‘new connector’ product programs for OEM auto makers; (4) direct reports, overall (50).

Project-managed Ford, Volvo, Chrysler, and Toyota connector & relay new product programs from initial design through feasibility studies, die-cutting, till mass-production approval. Applied advanced product quality planning [APQP] and production part approval process [PPAP] methodologies. Implemented quality management systems required by the automotive industry: MS-9000, QS-9000, ISO/TS 16949, & ISO 14001. Select Achievements:

Led a team tasked with the implementation of a lean manufacturing system – New Yazaki System (NYS) - modeled after Toyota Production System (TPS).

Education

MBA - U.T. EL PASO, TX

Languages

French, Arabic, and Spanish.

Systems

MS package, SAP, Oracle, AS400, MAPICS, SyteLine, SyteLean, I2B, Curtis Fitch... Certifications

Lean Six Sigma Master Black-Belt

Project Management Professional

ISO TS-16949 Lead Auditor

Advanced Product Quality Planning

Product Part Approval Process

Failure Mode & Effect Analysis

“We are what we repeatedly do. Excellence, then, is not an act, but a habit.” Aristotle

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