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Eng., Mfg., CI, Lean, 6 Sigma, Operations, Supply Chain, Management

Greensboro, North Carolina, United States
January 09, 2018

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John W. Spivey

BSME, Certified Six Sigma Black Belt

*** ***** ****, ***. **, Greensboro, NC 27407

Phone: 704-***-**** Email:


Customer and quality focused management professional with multi-site experience who provides strategic vision, communication and leadership that drives innovation, operational excellence, productivity, efficiency and bottom-line improvements.


Leadership, Engineering, Manufacturing, Lean, Six Sigma, Quality, Continuous Improvement, Operations, Project Management, Supply Chain, Strategic Planning/Implementing, Budgeting/Scheduling, Team Development and Engagement, Communication, Problem Solving/Decision Making, Negotiation


Energizer Holdings 6/2016 to Present

Design/Manufacture/Distribute Battery and Lighting Products

Manager, Lean & Continuous Improvement – NA

Problem Solving and Decision Making SME for North American operations

Hands-on high volume operations experience – over 2.0 Billion units produced in FY2017

Revised Tollgate Process to close gaps and include greater focus on critical KPI’s

Attacked High-speed automated process with chronic Quality problem; improving production as well as saving $519,000/yr in deviation generated scrap

Spearheading North American efforts to improve the Quality Management System, implement problem solving for more effective root cause analysis and develop more robust Quality Systems/Procedures, capture and disseminate “tribal knowledge” of pending retirees

Partner with vendors to improve their Quality systems and increase mfg. process efficiency

Consultant 1/2015 to 6/2016

Lean, Process Improvement/Development, OpEx

Drove ISO 9001:2008 and ISO/TS 16949 certification project for specialty outdoor power equipment manufacturer

Led transformation project for major CMOP (fulfillment and distribution) resulting in 20% capacity increase with no CAPEX – Automated fulfillment processes

Spearheaded quoting process streamlining project for significant manufacturer; reducing turnaround from (4) days to (24) hours

EPV Corporation and Metrolina Corporation 1/2014 to 1/2015

Automotive Develop/Design & Heavy Manufacturing/Fabrication – Hybrid Busses

Manager, Operational Excellence & Quality Assurance

Multiple Value & Process maps, developed and implemented plan to increase automotive manufacturer’s output 100% in 60 days and a follow up plan to increase output 400% in 120 days using Lean Methodology (involving Manufacturing, Supply Chain, Quality)

Capacity and production planning; implemented modified JIT Supply Chain model

Developed and led projects implementing assembly methods, standards and work instructions

Generated and implement plan resulting in ISO9001:2008 Certification for Metrolina Corporation

Regulatory/Compliance: DOT, OSHA, UL, CE, ISO

Consultant 8/2012 to 1/2014

Process/Operations Improvement

Operational excellence, continuous improvement leadership, Best Practices implementation, Process development and improvement; Business Turn-Around

Developed and implemented Supply Chain improvement project (6 US facilities) reducing inventory 54% and transitioned to a modified JIT system with no P&L impact

Reduced product costs by 17% and operating expenses by 21%

Prodigy Diabetes Care 6/2010 to 6/2012

Medical Manufacturing/Distribution

Plant Manager/Director of Engineering and Technology Development

Provided hands-on leadership to Engineering, Project Management, Manufacturing and Technology Development groups

Developed Value Stream and Process Maps of existing processes, which resulted in immediate savings of $110,000/yr

Developed and managed “Visual Factory” project for all (3) US facilities, reducing rework due to assembly error by 98%

Developed and implemented automated manufacturing and packaging production capability

Responsible for approval and budget/timeline development and adherence for all CAPEX, Product Development, R&D and facility expansion/upgrade projects, which streamlined the process saving an average of $150,000/yr

Utilizing TRIZ and Lean Six Sigma methodology, successfully managed manufacturing automation project, reducing planned CAPEX by 75% and planned start-up schedule by 50%

Regulatory/Compliance: FDA, UL, CE, ISO, OSHA

Washington Mutual 3/2007 to 3/2010

Banking/Financial Institution

VP/Manager of Operational Excellence

Led cross-functional teams through successful completion of Continuous Improvement projects

Hands-on implementation of and training in Six Sigma and Lean methodology

Tyco International 12/2000 to 3/2007

Safety/Life Saving Equipment Develop/Design/Manufacture

NPD Engineering Manager/Global Program Manager/Six Sigma Black Belt

Directly accountable for hands-on leadership of all New Product Development projects for the Breathing Systems strategic business unit.

Led multiple NPD projects from inception to commercialization, using DFSS and DMAIC Six Sigma and Lean methodologies

Increased bench depth and strength of Engineering teams

Co-developed and implemented NPD Tollgate process, decreasing ETO lead time by 33%, reducing “concept-to-market” time over 40%, improving projected ROI accuracy by over 90%, substantially reducing wasted effort spent “firefighting”

Successfully led global RoHS/WEEE compliance efforts for strategic business unit and saved $1.1M of $2M project budget

As “Change Agent”, led change management and culture change in transitioning privately held company to the results-oriented culture of new parent company; conflict resolution/mitigation

Regulatory/Compliance: FDA, UL, CE, TUV, NFPA, NIOSH, OSHA, CBRN, DOT


Winsor & Jerauld - GM/Dir. of Engineering/Manufacturing – Textile Machinery

GE Healthcare – Sr. Product Development Engineer – Large Medical Devices

DuPont - Project Engineer – Polyester Film Production


A.S. Mechanical Engineering Technologies, Chesterfield-Marlboro Technical College

B.S. Mechanical Engineering, LaSalle University

Certified Six Sigma Black Belt – DFSS (DMADV) & DMAIC, Tyco International and Quality Council of Indiana


U.S. Patent #5,828,280 “Passive Conductor Heater for Zero Boiloff Superconducting Magnet Pressure Control”

U.S. Patent #7,940,184 “Integrated Circuit and Method to Secure a RFID Tag”


Microsoft Office (Word, Excel, Outlook, PowerPoint), Microsoft Project, Visio, Minitab, AutoCAD

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