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Engineer Manufacturing

Charlotte, North Carolina, United States
August 10, 2018

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Charles S. DeChellis Jr.

Concord, NC *****


Quality Engineering Project Management Manufacturing

Results oriented and process driven leader with extensive manufacturing experience in a fast-paced, Fortune 500 company. Led international and cross-functional new and existing product teams with members in the US, China and Mexico. A proven track record in all areas from design phase, to execution, troubleshooting and production. Well versed in export safety regulations and exceptional cross-cultural communication skills. Key skill areas include:

Project Management New Product Development Process

Working w/Asian OEM’s Design for Manufacturing

Cost Reductions Quality Improvement

Financial Analysis Lean Manufacturing

Six Sigma Team Leadership


TTI Floor Care, Charlotte, NC 2013 - 2018

A division of Techtronic Industries Co., Techtronic Industries produces power tools and floor care products for the Milwaukee, Rigid, Ryobi, Homelite, Hoover, Oreck and Dirt Devil brands.

Directly managed and coordinated manufacturing, quality, purchasing and industrial engineering function teams located in Shenzhen, Dongguan and Suzhou, China. Directed engineering teams in El Paso, TX, and Juarez, Mexico, with up to 20-25 cross-functional members. Extensive travel to Asia, Mexico and within the US. Experience with all types of plastic processing, materials and molds.

Key Accomplishments

Developed and implemented a test plan for the new Oreck stick vacuum with POD technology which is new to the vacuum industry.

Directed and transferred to OEM’s in China 15 existing wet upright platforms with retail price between $99 and $300. These platforms will replace models with higher standard plant cost, resulting in Gross Margin improvement by 15% or more.

Led a 12 month project transferring 23 existing upright platforms to Cookeville, TN.

Launched “Hoover T-Series” vacuums in 2009 which resulted in more than 4M units and approximately $310M sold in two-and-one-half years. The platform approach allowed for retailer differentiation and a clear strategy for feature step-ups. Implemented 21 different models that replaced outdated and low margin products.

Managed the Plastic and Assembly OEM’s to ensure all production transferred from the United States to China met all manufacturing specifications.

Collaborated and communicated daily with various Product Development, Quality, Marketing and team members to ensure all product specifications were met.

Liaison with logistics department to ensure a smooth ramp up and inventory transition.

Maintain constant contact with United States and China teams on projects.

Coordinated a detailed product schedule to ensure all products met production needs.

Implemented timetables of moving manufacturing equipment and tooling to China.

Charles S. DeChellis Jr. 915-***-**** Page Two

The Hoover Company, El Paso, TX 1988 - 2013

Senior Staff Project Engineer 1992 - 2013

Project Engineer in the Office of the Manufacturing Engineering Division. Manufacturing liaison working with New Product Development Teams on new platforms from concept stage through production stage.

Coordinated implementation of 16 major projects, up to $20 million each for new models, capacity expansion, automation, cost reduction and product improvements.

Developed manufacturing plans for various product lines including method of manufacture, product costs including material, labor and burden, bill of materials, expenditures and timing required to implement projects.

Managed cost reduction program saving $38 million over 5 years. Met or exceeded corporate goals every year.

Key member of the WindTunnel project, one of the most successful new product launches; ranked #1 by Consumer Report.

Implemented a new co-molding process which garnered over $15,000 annual savings.

Produced a high-demand cost-effective cleaner attachment $250,000 under budget and 1 month ahead of schedule.

Expert cost-analysis and problem solving identified most effective mold runs, virtually eliminated down-time and guaranteed adequate inventory.

Achieved full production on Orion project 1-2 days ahead of schedule and facilitated package savings of $2.25 / unit.

Initiated digital photography process to identify and correct problems in production. Corrections were made within hours instead of days and shipping costs were eliminated.

Automated set-up system to structure production. Changes could be implemented in 1-2 days compared to 1 week manually.

Collaborated with IT to design MAS product cost documents which allowed side-by-side comparisons of prices. Eliminated cumbersome, time-consuming searching for information.

Senior Quality Analyst 1990-1992

Developed quality standards for new major manufacturing projects at all Hoover facilities.

Supplier Quality Analyst 1988-1990

Evaluated and audited supplier performance, from manufacturing process of raw materials to finished goods, for Preferred Supplier Certification.


Associate Degree in Business Management, Stark State College, Canton, OH

Mechanical Technology Classes, Stark State College, Canton, OH


Six Sigma and Lean Manufacturing Just In Time

Creo 2.0 Kanban

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