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Lean Six Sigma

Location:
Aliso Viejo, California, United States
Salary:
$155000
Posted:
November 15, 2018

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Resume:

MIKE KHAVAR

Laguna Niguel, CA 949-***-**** ac7pi1@r.postjobfree.com LinkedIn URL https://www.linkedin.com/in/mike-khavar-389a047/

QUALITY & PROCESS IMPROVEMENT SIX SIGMA LEADER

Multilingual hands-on multi-industry Lean Six Sigma experience resulting in delivering 6-7 multiple of my annual compensations to the bottom line of companies year after year. Experienced Lean Six Sigma trainer at all levels from floor personnel to engineers and Sr. managers. Have developed respective training material for all Six Sigma belts (White, yellow, green, black & master black belt) and all levels of Lean. Developed and managed large scale Continuous Improvement projects across multi-plants & multi-countries operations. Very passionate in living and practicing Lean Six Sigma culture and methodologies as well as inspiring and motivating team members throughout the company.

PROFESSIONAL EXPERIENCE

DJO GLOBAL, Vista, CA 2017 - Present

DJO is a leading global provider of high-quality, orthopedic devices, with a broad range of products used for rehabilitation, pain management and physical therapy. We also develop, manufacture and distribute a broad range of surgical reconstructive implant products.

Senior Manager, Global Quality Lean Six Sigma

Responsible for the overall coordination and management of the DJO Global Quality Lean Six Sigma initiatives to develop, manage and lead the execution of short and long-term projects that require organization, research, analysis, planning, development, communication and/or coordination between departments within the company.

•Saved $2.4M ($3.8M Run Rate) developing and executing 63 COPQ projects in 2017 against a corporate goal of $1M.

•Managed a direct report team of 25 Six Sigma black green belts & engineers at 7 manufacturing and distribution sites world-wide.

•Spent 50% of time at the Tijuana, MX manufacturing site with over 4000 employees streamlining processes at over100 MFG cells.

•Spent 50% of time at the Tijuana, MX manufacturing site with over 4000 employees streamlining processes at over100 MFG cells.

•Value stream mapped all locations manufacturing cell processes identifying over 1400 non-value added activities

•Developed a real time dashboard to track all operational KPIs

•Developed a 64-hour CSSGB training material and trained a total of 285 individuals in 2017.

•As part of the corporate Customer Enhancement initiative, managed Complaints Per Million (CPM) reduction projects to achieve a corporate goal of 700 CPM in 2018, a 50% improvement over 2017. All 38 projects were SSBB level projects following the DMAIC methodologies to reduce # of customer complaints world-wide.

ARROWHEAD PRODUCTS, Los Alamitos, CA 2016 - 2017

Arrowhead Products is a world leader in the design, development and manufacture of ducting systems for aircraft and propulsion lines for rockets.

Continuous Improvement Team Lead (Consultant)

Consulting contract to lead a team of 12 Lean Six Sigma Green and Black belts to implement continuous improvement initiatives across the joint NASA & Boeing Space Launch Systems (SLS) business units.

•Led and owned process improvement projects across the enterprise netting $1.6M in 6 months.

•Collaborated with SLS business unit to understand needs, map current states, design future states, and deployed sustainable processes.

•Performed root cause analysis and recommended best practice solutions to increase throughputs by 60%.

•Designed, developed and executed high level business analytics using Lean six sigma skills to reduce NVAs across manufacturing cells by 80%.

•Ensured that recommended changes are implemented and that forecasted cost savings, efficiency gains, etc. are realized.

•Provided senior leadership support for continuous improvement strategies in accordance with the organization’s policies and applicable laws.

•Consulted in the design (DMADV) and optimization of business processes (DMAIC). Also assisted in the design of process reporting dashboards for maximum sustainability.

•Educated, trained and supported 85 process owners in applying Lean six sigma methodologies.

CARL ZEISS MEDITEC, Ontario, CA 2015 - 2016

ZEISS is an international leader in the fields of optics and optoelectronics. ZEISS has been contributing to technological progress for 170 years – with solutions for the semiconductor, automotive and mechanical engineering industries, biomedical research and medical technology, as well as eyeglass lenses, camera and cine lenses, binoculars and planetariums.

Lean Six Sigma Champion (Consultant)

Consulting contract to streamline the entire Biomaterials & Hydrophobic & Hydrophilic IOL’s manufacturing processes by applying various Lean Six Sigma methodologies such as 1 piece flow, SMED, TPM, Kaizen events, Poke Yoke, 8S, Heijunka, Visual Factory, ANOVA & DOE’s to enhance MFG footprints and manpower utilizations. The following completed projects had netted $2.6M in hard savings:

•Project 1: Hydrophobic- Machining Cell Process Improvement (PI)

•Project 2: Hydrophilic- Machining cell PI

•Project 3: Three Piece Lenses drilling, Assembly & cleaning PI

•Project 4: Packing PI

•Project 5 : Hydrophobic- Clean Room PI

•Project 6: Hydrophilic- Clean Room PI

•Project 7 : Heparin PI

•Project 8 : Shipping PI

•Project 9 : Biomaterials PI

•Implementation of Daily Management Systems (KPI’s) in all key processes

MASIMO CORPORATION, Irvine, CA 2011 - 2015

A global medical technology company that develops and manufactures innovative noninvasive patient monitoring technologies.

Global Lean Six Sigma Champion

•Developed a successful strategy and drove execution for delivering product at the quality, cost and speed driven by the market.

•Integrated efforts across the enterprise to ensure a focused and consistent approach for optimizing and standardizing processes.

•Delivered breakthrough levels of improvement in process capability and design for manufacturability to reduce defects and attain world-class quality levels – DFLSS. Total annualized Run Rate savings of $1.4M.

•Developed the following training material and trained over 3000 employees across US, Mexico, Europe, Brazil, Japan and Turkey:

oCertified Lean Expert (CLE) 16 hrs

oCertified Lean Six Sigma Green Belt (CLSSGB) 80 hrs

oCertified Lean Six Sigma Black Belt (CLSSBB) 160 hrs

oExecutive Champion (EC) 4 hrs

oCertified Kaizen/5S Expert (CKE) 8 hrs

oCertified Supply Chain Operations Reference (CSCOR) 20 hrs

oCertified Design For Lean Six Sigma (CDFLSS) 20 hrs

•Identified, prioritized and executed a collection of 33 LSS/Kaizen process improvement projects across the enterprise with a total annual savings of $2.7M.

•Linked LSS activities to business objectives by developing and maintaining detailed Value Stream Maps, Control Plans and standardized metrics for key processes.

•Created visual factory with story board components across the enterprise for team members and Sr. management to monitor and gauge the progress of the active LSS projects.

•Spent 50% of time at the Mexicali, MX manufacturing site with over 3000 employees streamlining processes at over100 MFG cells.

WARMELIN PRECISION PRODUCTS, Hawthorne, CA 2010 - 2011

An aerospace components and assembly manufacturer.

Director, Quality & Continuous Improvements

•Managed a staff of 15 engineers, supervisors and QA auditors.

•Identified, prioritized and executed strategic continuous improvement initiatives to ensure successful achievement of committed company objectives.

•Obtained ISO 9001-2008 and AS9100C certifications.

•Developed a successful Supplier Certification Program and monitored their performance.

•Developed training material for Lean, Six Sigma, Kaizen and 6S and trained a total of 89 managers and employees accordingly.

•Developed, implemented and maintained meaningful metrics such as OTD, PPM, Inventory Turns, Sales per Employee and Quick Ratio for daily review by team members and management.

•Developed and implemented SCOR (Supply Chain Operations Reference) across the entire supply chain streams to ensure timely delivery of defect-free products. After 6 months, RI has been reduced by 90%.

•Instituted a “8D & 5 why” problem solving policy to pinpoint the true root causes of process anomalies to prevent recurrence.

•Primary person to Interface with customers, suppliers and 3rd party certifying bodies.

•Developed detailed VSMs for key processes to decrease NVAs across all MFG cells by 56%.

AIT BUSINESS SOLUTIONS, Chandler, AZ 2007 - 2009

An international business improvement consulting firm.

Global Lean Six Sigma SCOR Consultant

Engaged in worldwide clients in the financial and manufacturing sectors with a portfolio of business optimization solutions designed to help them achieve competitive advantage and increase customer satisfaction. Provided coaching, mentoring and training to various clients in the following fields:

•Competitive Strategy & Innovation

•Value & Opportunity Identification

•Value Chain Transformation (SCOR)

•Lean Six Sigma & DFSS Deployment

XPECTRA, INC., San Diego, CA, Niwot, CO, Tijuana & Juarez, Mexico, 2003 – 2007 A General Electric Company that is multi-faceted custom injection molding company serving electronics, automotive and medical industries with one US and three Mexican operations.

Vice President, Quality & Business Excellence

•Served as a change agent and constant proponent of Six Sigma within the organization to drive the execution of key deliverables and metrics.

•Drove Customer Satisfaction through focus on service and on process improvement initiatives. Completed GB/BB projects and coached and mentored GB/BB projects to deliver targeted improvements.

•Worked with functional organizations to identify strategic goals, establish business wide metrics and formulate actionable work plans.

•Drove projects aligned with the Growth Strategies across the business using DMAIC & LEAN tools and mobilizing cross-functional teams.

•Developed a thorough hands-on understanding of and led efforts to map business processes. Identified and executed on opportunities for improvement using observation, root cause analysis, process mapping, piloting and structured analysis including metrics and control plans. Established relationship with customers to determine Critical-To-Quality characteristics and to learn effects of process changes.

•Developed training material and trained 45 Green and Black belts across the organization.

RAINBIRD CORPORATION, Azusa, CA 2001 - 2003

Manufacturer of irrigation related products.

Six Sigma Specialist (Consultant)

•Led the division’s lean enterprise initiatives by implementing six sigma metrics throughout the plant of 350 employees.

•Implemented necessary infrastructures for the obtainment of ISO 9001-2000 by writing manual and procedures.

•Developed measurement methodologies, inspection strategies and process improvements to reduce defects and improve quality.

•Developed a PPAP process to certify internal and external injection molding suppliers for a Dock-to-Stock initiative. Oversaw process capability studies, corrective action and material non-conformance systems.

•Provided training and technical assistance to division associates in the application of Six Sigma. Developed, monitored and reported on key measurements associated with the operations to senior staff. Implemented an Integrated Product Development Management System (IPDMS) for new product launch.

ROBERTSHAW CONTROLS COMPANY (AN INVENSYS GROUP COMPANY), Long Beach, CA & Mexicali, Mexico

1998 - 2001

The world’s leading gas control and systems provider for the water heating, central heating, and space heating markets.

Senior Customer Quality Manager

•Provided leadership and direction in aligning Six Sigma methodology with the business goals.

•Responsible for developing strategic plan for multi-plant operations for first time roll-out, educating business teams, allocation of resources; heavy focus on increasing customer satisfaction/loyalty, reduce process/operations costs, designation of key processes requiring re-engineering or improvement, and defect reduction programs. Budgeted and deployed managers, engineers, and supervisors in a manner that encouraged quality improvement and increased effectiveness.

•Understood and led efforts to apply Customer Focused Quality (QFD) principles on the daily practices.

•Directly accountable to assure all quality demands are met on schedule and within budget. Implemented Six Sigma metrics that provided data for process management / indicators for future improvement opportunities.

Six Sigma Specialist (Consultant), THE BOEING COMPANY, Long Beach, CA

1995 - 1998

Senior Quality Project Engineer, SUNDSTRAND POWER SYSTEMS, DIVISION OF SUNDSTRAND CORPORATION, San Diego, CA

1985 - 1995

EDUCATION

MS, Operations Management with emphasis on, Industrial Technical Management

BS, Bachelor of Science, Industrial Engineering

Central Connecticut State University, New Britain, CT

MILITARY EXPERIENCE

SUNY, MARITIME COLLEGE, Bronx, NY

US COAST GUARD ACADEMY, New London, CT

CITADEL, Charleston, SC

CERTIFICATIONS

ASQ Certified Six Sigma Black Belt

Certified Six Sigma Master Black Belt Lean Bronze Certified

LANGUAGES

English Full professional proficiency

Farsi Native

Spanish Professional working proficiency



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