Manager Six Sigma

KENNETH S. SPANGLER

**** ******** *****

Asheboro, North Carolina 27205

336-***-**** home

336-***-**** cell

********@*****.***

Employment Objective

To further a career in Operations/Plant Management and Lean Six Sigma

Enterprise.

Education

1. MBA from UNC at Greensboro (May 1999)

with emphasis in Operations and Process Improvement.

2. BS in Electrical Engineering (July 1984) from Virginia Polytechnic

Institute &

State University (VPI&SU) in Blacksburg, Virginia.

3. Cooperative Education Program at IBM (Federal Systems Division) in

Manassas, Virginia (July 1980 - December 1982).

-Sonar Q5/Q6 System Engineering/UYK-44 Hardware Design/Diagnostics

Engineering/Memory Chip Semiconductor Characterization Laboratory.

4. ASQ Certified Six Sigma Black Belt (CSSBB), October 2004.

5. ASQ Certified Quality Engineer (CQE), June 1993.

6. ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE),

March 1998.

7. ASQ Certified Quality Auditor (CQA), June 1994.

8. HACCP Workshop, NC State University, Raleigh, NC, (14-16 October 2003)

9. Zenger-Miller Certified QUEST Instructor, January 1993 (TQM Skills

Training).

10. Design Of Experiments (DOE) Training B&D (40 hours, including project

February 1997).

11. Six Sigma Champion Training Mohawk (24 hours, August 2008)

Experience

Consolidated Container Company LLC in Greensboro, North Carolina

Plant Manager, June 2012 to November 2013

12. Responsible for 24/5 blow molding operation producing Food Grade HDPE

and PET dairy, water, juice bottles to customers in VA, NC, SC and TN

13. Reduced Monthly Resin Scrap from $84,000/month to less than

$1,000/month using lean six sigma techniques.

14. Six Sigma Project Determined bottle weight process capabilities,

trained operators to steer bottle weights averages to lower end of

specification, generating material savings of $10,000/month

15. Support and maintain 7 HDPE and 2 PET blow molding production lines

16. Continually drive Safety, Quality, FPY and Uptime improvements across

the Greensboro plant.

17. Lead Maintenance Manager, 3 Production Supervisors, Scheduler and

Administrative Assistant and 17 hourly Team Members.

18. Continually optimize processes using lean six sigma techniques.

19. Communicate Plant KPIs daily using visual process trending tools and

personal interactions.

20. Implemented "visual" process trends for quality and production in all

production areas, including Maintenance areas.

21. Request CAPX funding and manage timely completion of capital projects.

22. Develop SOPs and Checklists to minimize process variation across 3

shifts

23. Developed Good Manufacturing Practices (GMPs) and trained all team

members.

24. Regularly meet with all Dairy, Water, Juice customers (Dean Foods,

Alamance Foods, Artesian Waters) to resolve any issues.

25. Host all regulatory food safety audits from NCDA&CS, USDA and Silliker

26. Participate with Sales Team to bring new business to Greensboro.

ARAUCO Panels USA LLC in Moncure, North Carolina

MDF Operations Manager, April 2011 to June 2012

27. Responsible for 24/7 plant operations for the largest HDF, MDF, LDF

production facility in the US, reporting to Plant Manager.

28. Reduced losses from $1MM/month to breakeven through machine uptime and

process improvements.

29. Continually drive uptime improvements and focus on top 5 priority

actions by area

30. Lead 1 Finishing Manager, 3 Process Leaders (Wood Yard/Energy,

Refiner/Drying, Forming/Press), 4 Production Supervisors and 60 Hourly

Team Members.

31. Continually optimize processes using lean six sigma techniques.

32. Communicate Plant KPIs daily using visual process trending tools.

33. Implemented "visual" process trends for quality and production in all

production areas, including Maintenance areas.

34. Manage timely completion of CapEx projects.

35. Develop SOPs and Daily SCMs (standard condition monitoring) checksheets

to minimize process variation across 4 teams.

36. Developed Good Manufacturing Practices (GMPs) and trained all team

members.

37. Meet with external customers (PERGO) to resolve issues. Develop "win-

win" solutions in Sales Team.

38. Review downtime daily, develop action plans for top 10 issues in each

area.

39. Six Sigma Project Use Kaizen "Just Do It" process to implement

continuous improvements (5S+1 and SMED).

40. Implemented rotating 12 hours shifts to improve skills levels of all 4

teams.

41. Developed optimized staffing plans to increase uptime and improve

morale.

42. Active Member of Safety Committee

Mohawk Industries in Thomasville, North Carolina

Production Manager, August 2005 to April 2011

43. Responsible for 24/7 press operations for two highly automated Wemhoner

press lines supporting glueless laminate flooring production.

44. Responsible of scrap reduction efforts and production TME (Performance,

Availability, Quality).

45. Startup/completion of green field construction of facility at

Thomasville site next to Interstate 85.

46. Responsible for capital purchase of 100 chrome engravings/press plates

(~$10MM)

47. System integrator / trainer for SAP, Locus warehouse, other custom

scheduling and process control tools.

48. Provide R&D support of new product developments, including High Gloss

Laminate and other new innovations.

49. Six Sigma Project Developed, implemented innovative statistical test

methods (UV Cure, UV Porosity, Gloss, Bow) in production environment.

50. Central Safety Chair-Auditing (modeled after Dupont initiative)- lead 4

member multi-functional team to improve plant safety processes.

51. Established Preventive Maintenance Weekly, Monthly, 3-month and Annual

Checklists.

52. Six Sigma Green Belt Instructor

53. Six Sigma Project - Implemented networked process control system using

BIS.NET for uv cure, uv porosity, gloss, bow, with dynamic specifications

resulting in less quality holds for improper cure, less complaints from

internal customer cutting and milling, less human errors.

54. Direct 35 Team Members: 1 Maintenance Supervisor, 5 Electronic

Technicians, 1 Mechanic, 1 Process Engineer, 1 Tooling Coordinator, and 4

Shift Leaders Supervisors, 20 Operators, 2 Temporary Workers on 4 Shifts.

55. Implemented annual cost savings > $750K (developed local chrome plater,

scrap reduction, SMED quick changeovers, raw board formulation changes,

press pad material and auto-tensioning,

56. Led 28 Kaizen Events to improve processes (Process Proofing, SMED, DOE,

5-S, Visual Kanbans, etc) using lean six sigma tools.

57. Traveled internationally to provide technical support to our suppliers

and sister plants (Germany, France and Belgium).

Multi-Wall Packaging Corporation in Salisbury, North Carolina

Operations Manager - Hard Angle & Real Reel Divisions, August 2004 to

August 2005

58. Responsible for Profit & Loss Performance of 2 Divisions with $10MM in

Sales (4-walls, entire facility),

reporting to VP-Manufacturing - Southern Region.

59. Took Hard Angle/Reels manufacturing processes to the next level using

Lean Six Sigma Tools.

60. Directed 40 Hourly Team Members, 1 Maintenance Technician, 1 Lead, and

2 Supervisors on 2 Shifts.

61. Staffed a 3rd Shift Team due to sales growth in Hard Angle Division.

62. Reduced waste from 20.3% to 10% after 5 months in facility.

63. Designed the next generation Hard Angle Forming Process Line, including

safety devices.

64. Kaizen Event to improve Off-line Paper Slitting process using SMED

techniques.

65. Developed all performance plans and budgets for Hard Angle & Reels

Divisions

66. Setup product warehousing and "pull" flow into customer's facility (HON

Office Furniture) in Richmond, VA.

Unilever in Asheboro, North Carolina

Operations Senior Shift Manager, January 2003 to July 2004

67. Managed 1st Shift Operations in Warehouse, Mix, Packaging Departments

for the Asheboro Dry Soup/Sauce/Dessert Plant (Lipton, Knorr, Slimfast,

Legout brands, including USDA surveillance).

68. Directed and coached 53 Team Members and ~ 20 Temporary Workers on 1st

Shift, including 3 Department Coordinators.

69. Six Sigma Project - Implemented networked process control system for

weight control on state-of-the-art 700 ppm pouch filler machine,

resulting in over $1MM annual materials cost savings (toasted and white

onions for Lipton Onion Soup Mix).

70. Involved Team Members in Autonomous Maintenance steps on two high speed

packaging lines (team members identified needed repairs and performed

some PMs (freeing up valuable Maintenance resources).

Pass & Seymour/Legrand in Concord, North Carolina

Quality Assurance Manager / PITeam Leader, March 1998 to December 2002.

71. Managed all aspects of Quality for the Concord Plant (Electrical Wiring

Devices, GFCIs, Commercial/Hospital Grade Switches and Receptacles, Metal

and Plastic Wallplates, Pin and Sleeve products).

72. Designed/Implemented/Championed Lean Six Sigma process called PITeams.

(January 2001). PITCrews use various Black Belt Tools, 5-S, Process

Proofing, SPC, Cpk, DOE, SMED, Kanban, Value Stream Mapping, Visual Cues,

etc.

73. Six Sigma Project - GFCI Latch Spring Redesign (eliminated rework due

to sensitive units saving over $1,000,000)

74. 30 PITeam Events completed, resulting in over $250,000 annual savings,

"LEAN" culture change at multiple plant locations, over 250 employees

trained to use Lean Six Sigma Tools.

75. Regularly demonstrated ability to broker solutions to difficult plant

issues (i.e. Lean One-Piece Flow Vision and Product Issues).

76. Managed the activities/projects of 2 Quality Engineers, 11 QA Auditors,

12 ISO Internal Auditors, 1 Quality/CMM Technician and 1 Document Control

Administrator (DAC).

Black & Decker in Asheboro, North Carolina

Business Team Quality Assurance Engineer, November 1992 to March 1998.

77. Managed all aspects of Quality for the Cooking Business Team (4-Slice

Toast-R-Ovens (TROs), 6-Slice TROs, Horizontal Toasters and Metal

Stamping Operations). Sales: $150MM. Annual Volumes: 3.5MM units (15-

17K units per day).

78. Supervised 1 Quality Engineer, 2 Quality Technicians, 1 Quality

Assistant.

79. Gave direction/written instructions to 8 End-of-Line Auditors, 4

Receiving Inspectors, 1 Metrologist, 1 CMM Specialist, 2 Lab Technicians.

80. Facilitated solutions to all production problems (i.e. process

improvements, repair/upgrade equipment, rework procedures, supplier

issues).

81. Developed all Quality planning documentation (APQPs, PPAPs, Design and

Process FMEAs, Process Capability Studies, GR&Rs, Receiving Inspection

Plans, In-process Control Plans, Final Product Audit Plans, Product

Quality Reports).

82. Designed and implemented a networked in-process data collection / SPC

system for the Asheboro Plant using state-of-the-art Change Analysis

Techniques (PC-calculated Moving Averages chart, not traditional X-bar &

R charts)

83. Six Sigma Project - Implemented Oven/Toast SPC applications on 5 TROs

lines reducing oven rework/recalibration by 20% ($835K Annual Savings).

84. Kaizen Facilitator, Team Leader, Team Member. Trained by TBM Consulting

Group, Durham, NC

85. Traveled internationally to support suppliers and sister plants (China,

Singapore, Malaysia, Hong Kong, Mexico and U.K.).

Sperry Marine Inc. in Charlottesville, Virginia

Quality Assurance Engineer, November 1988 to November 1992.

86. Managed military quality programs for Ring Laser Gyro Inertial

Navigators (compasses), Periscopes, rasterscan radars, depth gages, etc.

87. Supervised 6 QA Analysts and 1 QA Assistant.

88. Customer interface (i.e. U.S. Navy/NATO/Australian Navy/FAA) for all

matters related to Quality.

89. Performed Source Inspections/Quality Audits at Supplier facilities in

the U.S. and internationally.

Teledyne Avionics in Charlottesville, Virginia

Quality Assurance Engineer, August 1984 to November 1988.

90. Managed military/commercial quality programs for Angle of Attack (AOA)

Transmitters for attack class fighters and business jets, stall warning

computers, inertial vertical speed indicators (IVSI).

91. Supervised all Electrical/Mechanical Calibration and Test Equipment

Repair (3 Technicians in Calibration Laboratory).

92. Designed/Built Computer-controlled Reliability Burn-in Systems for

Military Avionics applications.

93. Customer interface (i.e. U.S. Government/McDonnell Aircraft/General

Dynamics)

94. FAA Certified Instrument Repairman

Skills

95. Expert PC user/developer including: SAP, JDE Business Objects,

Ceridian, Concur, Oracle, MS Office, including MS Access, MS Project,

Visio Flow Charter, Statistical softwares Minitab, Quality America, DOE

Pro XL, SPC XL, and QIS2000, CorrectiveAction5, Network Administrator.

Professional Activities

96. American Society for Quality (ASQ) since 1984. - Senior Member

97. Institute of Electrical and Electronics Engineers (IEEE) since 1979.

98. Submitted Technical Paper on Kaizen for the 1997 Shingo Quality Award

at Utah State.

99. Wrote Technical Paper on Gainsharing Implementation Strategies as part

of MBA studies.

Interests

100. Married for 29 years.

101. 2 daughters (21 and 17 years old).

102. Photography, road biking, all racquet sports.

References available upon request.

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