Quality Assurance Six Sigma

Thomas Bogucki

Director of Manufacturing at GE Healthcare

acb6ro@r.postjobfree.com

Summary

Lean Six Sigma Master Black Belt, Manager Lean Manufacturing, Root Cause Analysis & Product Reliability

Testing, Strong technical knowledge and "hands-on" skills in fast paced manufacturing environment. Expertise

in troubleshooting, analysis, process optimization and problem solving techniques

Experience

Director of Manufacturing at GE Healthcare

August 2011 - Present (2 years 6 months)

Director of Manufacturing for a world class manufacturing site that produces single patient use anesthesia

medical devices in a FDA regulated environment (over $100MM in annual revenue)

Responsible for daily operations, managed a cross-functional team to achieve cost, quality, and delivery

goals ( 4 manufacturing managers and 1 manufacturing engineer direct reports) managed the daily operations

of 200 production associates, driving business critical metrics (Safety, quality & productivity)

Mentored & motivated a diverse workforce. Accomplishments included the development of new attendance

policies and performance management metrics that improved work environment and culture. We were able to

achieve 95% service levels as a result of these programs

Co-Owner of EHS/ergonomics element program that aimed to improve shop floor working conditions

through the utilization of ergonomics and human organizational performance.

Developed & implemented a scrap reduction program that yielded over $70K savings annually

Successfully implemented programs to drive Lean concepts and continuous improvement.

Managed and implemented new capital equipment projects to enable company growth. Worked directly with

equipment suppliers to design, build, validate & implement new technologies to improve output

Worked with cross-functional peers in manufacturing engineering, planning, quality, to resolve issues and

drive continuous improvement utilizing Lean methodologies and tools

Developed, coordinated, led, lean manufacturing activities across multiple sites and ensure progress while

tracking project status and closure for over 200 employees

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Created a lean vision and implemented a lean strategy to reduce cycle time, inventory, and waste, executed

daily production plans to achieve 95% customer service satisfaction levels

Lean Manufacturing Engineer at Bath Iron Works

June 2009 - August 2011 (2 years 3 months)

Responsible for driving implementation of state of the art shipbuilding technologies, identifying, analyzing

and applying new technology and processes in ships construction (DDG 51 Arleigh Burke Class, DDX 1000

Zumwalt Class destroyers)

Conducted impact assessments for new technologies in ship construction, directed multi-functional teams in

problem solving efforts to reduce variation, increase customer satisfaction and improve financial return

Applied process mapping and value stream mapping to identify and eliminate waste and no-value added

activities throughout the ships construction process

Recommended revision of methods of operation, material handling, and equipment layout to help increase

production and improve standards

Responsible for implementing modifications to existing quality and production standards to achieve optimum

quality and evaluating data, and writing reports to validate deviations from existing standards

Utilized Six Sigma tools to analyze, identify, and drive process improvement opportunities that contributed to

product quality, productivity and minimize cost

Developed and led projects to meet operational performance targets and business operating plans

Ensured teams used time efficiently by using meeting management techniques, decision making strategies

and planning tools, as well as completing projects on time

Conducted ten Kaizen events per year, yielding over seven thousand hours in production savings from cost

schedule quality improvements

Worked closely with quality champions and operating leaders to develop project deployment strategy, goals

and priorities

Conducted theory of constraint projects resulting in an improvement of schedule by four weeks with 50%

fewer hours

Senior Quality Engineer at Regal Marine Industries

December 2002 - June 2009 (6 years 7 months)

Responsible for the overall coordination & integration of Quality Assurance activities including

safety/reliability & quality products produced for all Regal model types, responsible for $32 million dollars in

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annual production

Responsible for setting quality standards, specifications, inspection plans, and analyzing results in a fast

paced manufacturing environment using Kaizen, Lean Six Sigma, Kanban, 5S, and Root Cause analysis

Conducted Continuous Product and Process Improvements using Lean Six Sigma and Lean manufacturing

methodologies on Regal yachts to determine the required actions for improvement

Conducted evaluations, including design of experiments and reliability studies, when necessary to verify that

Regal products comply with requirements of applicable specifications including NMMA-ABYC standards

Responsible for creating Quality Control Procedures, reviewing documentation and product reliability testing

using diagnostic/computer systems to diagnose & trouble shoot engine/control related systems on yachts

Performed audits using Six Sigma, & ISO9001 guidelines during manufacturing process, reviewed blueprints

with Industrial Engineering Department

Appointed Audit Team Leader ISO9001 Audit team, overseeing internal and external audits, scheduling, and

effectiveness, and developing team members to achieve their fullest potential

Provided supervision to QA Technicians, Auditors, and Inspectors by leading cells to reach Six Sigma goals

at the direction of the Director of Quality Assurance

Performed ocean testing, lake testing as well as in house tank testing on all company yachts, maintained U.S.

Coast Guard license by performing on water yacht testing

Recognized for abilities in troubleshooting processes, managing manpower based on accurate installation

skill sets

Worked closely with sales & service, resolving customer issues, developing cost saving projects, bringing

vendors “In House” to perform Certificate of Inspection

Senior Captain/Night Manager at New York Waterway

June 1998 - November 2002 (4 years 6 months)

Responsible for coordination of quarterly bids for 55 Captain and 120 crew shifts

Directly organized nightly vessel planning and docking positions of over 42 ferry boats

Ensured efficient day to day running of ferry transportation operations and provided managerial support

Responsible for testing and eventually clearing new captains on vessels

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Directly supervised all officers and crewmembers, who operate engines, perform maintenance, handle lines,

or operate vessel

equipment

Insured that proper procedures and safety practices were performed, oversaw loading and discharging of

passengers, ensured safe transportation of 70,000 daily passengers

Assumed overall command of the operation and navigation of vessel in a safe and prudent manner

Determined course and speed of vessel, as well as maneuvering vessel to avoid any hazards

Coordinated safe and effective evacuation procedures for over 150,000 passengers during 9/11 tragedy

Worked closely with FBI, NYPD, U.S. Coast Guard, and other Government officials transporting officials

and classified materials following 9/11, helped set up mandatory de-contamination center in Weehawken, NJ

terminal for passengers on 9/11

Skills & Expertise

Six Sigma

Quality Assurance

Lean Manufacturing

Manufacturing

Process Improvement

Root Cause Analysis

Inspection

Project Planning

Quality Control

Testing

Kaizen

Software Documentation

Certifications

Lean Six Sigma Master Black Belt

Villanova University November 2011

Education

Villanova University

Certification, Certified Lean Six Sigma Black Belt, 2008 - 2008

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Villanova University

Certification, Six Sigma Green Belt, 2007 - 2007

Fairfield University

BS, Business Management, 1994 - 1998

Interests

Traveling, boating, sports

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Thomas Bogucki

Director of Manufacturing at GE Healthcare

acb6ro@r.postjobfree.com

Contact Thomas on LinkedIn

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Contact this candidate