Project Manager Six Sigma
Resume:
Mark E. Cargill
Home:
Marina Del Rey, CA 90292
Email: *********@*****.***
Objective
To obtain a position that will enable me to utilize & facilitate my
manufacturing & engineering skills and educational background to provide
continuous improvement using Lean & Six Sigma methodologies.
Education
Mott College-Flint, Michigan
Associates - Mechanical Engineering
Baker College - Jackson, MI
Bachelors in Business Leadership
Six Sigma
Certified Green Belt
Concentration in Manufacturing: Lean Manufacturing, TQM, TPM,
Process Control, FMEA, Production Management, Autonomous Maintenance,
Continuous Improvement, and Six Sigma Methodologies.
Work Experience
Armstrong World Industries Jun 2013 -
Current
Lean Master Engineer
. Establish 12 month Hoshin Calendar for 2014 using VSA & VSM process to
generate $3.2 Million savings plan.
. Charter each project on Hoshin Calendar to ensure assigned engineers &
managers are on track with saving plan.
. Lead weekly business meetings with management staff & engineering to
identify gaps in performance generating countermeasures to ensure
issues are addressed based on the top 3 negative financial drivers.
. Schedule weekly individual project reviews with Lean Managers and
Plant Manager, to facilitate lean practices and methodologies are
utilized delivering project savings as planned.
. Lead daily Gemba walk reviewing visual management performance tracking
boards, process control plans, and 5S lean principles are adhered to.
. Manage Hoshin project execution from inception to completion,
including communication of results and both process & financial
verification.
. Implemented process control plan with hourly monitoring of Key Process
Indicators driving a proactive behavior from a reactive behavior.
. Facilitate monthly Kaizen workshop to improve processes throughput,
eliminate waste, improve safety & quality, and drive OEE.
. Deliver weekly report out on key financial indicators for North
America Board of Directors.
. Provide monthly deployment report with countermeasures to North
America Board of Directors.
- 27% improvement in the commercial line throughput from a Kaizen
event.
- 6% yield improvement in residential tile line from one Kaizen
event.
- $789,000 savings elimination TI02 and using opaque film from VSA
event.
- Budgeted savings of $3.2 million in 2014 from VSA & VSM event.
- Implemented weekly production tracking charts trending
performance data managing key down day maintenance activities.
- Implemented 5S program with audit procedure to sustain
housekeeping improvements.
- Awarded $225,000 training grant by the State of California after
a 3 month application criteria with a detailed plan for 2014
covering the objectives and benefits to employees.
Glass Apps - Culver City, CA
Jan 2013 - June 2013
Production Manager / Lamination Expert
. Review weekly production schedule to ensure 100% on-time delivery.
. Facilitate structured daily & weekly meetings and reporting to ensure
continuous improvement.
. Assist technical support team with resolving technical issues using
DOE's and Six Sigma tools & Lean principles.
. Review performance daily metrics to ensure customer requirements are
sustained in safety, quality, and throughput.
. Provide engineering support implementing best practices for glass
lamination process, implement work instruction modifications, and
support training for the manufacturing team.
. Mentor supervisors providing career growth and development.
. Implement production best pratices.
Southwall Technologies
Jan 2009 - March 2012
North America Automotive Engineer
. Launching 2011 Automotive Glass Platforms using Solar Reflective Films
. Provide eight step problem solving techniques to achieve quality and
throughput budgeted goals.
. Support automotive manufacturing plants with technical concerns
processing solar reflective automotive films.
. Manage ANSI test procedures for qualification of new product.
. Perform transmission, reflective and aging studies on renewable
reflective films.
. Developed with a team of 4 engineers and collaborated with several
suppliers in the development of a patent-pending automated production
process for insulated glass units.
. Developing and testing new coated film solutions for automotive
glazing applications. Verification of durability, performance, and
value in the final form of energy glazing products used by customers.
Pilkington - Clinton, Michigan
March 2000 - March 2007
Team Leader/Six Sigma Green Belt
. Develop, monitor, and ensure achievement to the operation's annual
goals using boss charts to manage continuous improvement activities,
while providing operational leadership to the local team members and
maintaining organization accountability.
. Ensure safety audits were in compliance and obtain plant safety
budgets.
. P&L responsibility for seventy-percent of the plant's volume.
. Direct reports including, Process Engineers, Quality Engineers,
Supervisors and hourly employees (Production/Maintenance).
. Implement TPM & 5S in production processes and track compliance for
exceed budgeted goals.
. Managed and utilized CMMS to manage TPM, Maintenance Work Order
Management and Analysis and Inventory/Purchasing of spare parts.
Used extensive data for Reliability Analysis.
. Generated weekly down-time charts for review with maintenance team
to generate continuous improvement projects.
. Lead Work Standardization in production departments and
implementation of lean best practices.
. Material's Management or Inventory Control.
. Prepare annual Operating Budget & monthly forecast based upon actual
performance and changing customer needs.
. Managed all quality aspects of manufacturing
. Ensure completion of customer PRR/CAR-QPI/QPR FMEA and completion of
8D customer quality guidelines were followed.
. Developed Internal Audit procedure to focus on KPC, KPI, & quality
complaint issues.
. Establish internal audit procedure pulling finish goods from
warehouse to spot check product validation.
. Maintain quality skills training matrices for all operators and
ensure 100% compliance with QS.
. Monthly financial reporting and financial analysis for senior
management.
. Support customer to ensure requirements are achieved from pilot
proto-type build through build out of program.
- Led GMT 200 PPM Project to reduce customer buybacks
and reduced PPM to Budgeted Level / increasing internal
Yield by 1.5% resulting in a savings of $178,000
savings annually.
- Led GMT 200 Encapsulation process to a throughput increase of
400 pieces per shift Increased throughput from an
average of 1,150 pieces per shift to an average of 1,550 pieces
per shift. Annual savings of $580,000.
- Led CK Windshield MMPP labor Reduction by 33% by reducing manning
by 33% from installation of robotic mold
Release spray system project resulted in $280,000 savings
annually.
. Led GM Assembly team implementing glass assembly locating fixtures
- Reduced three operators decreasing assembly time and eliminating
assembly fit issues
- Project resulted in $425,000 annual savings
. Led GM Assembly team eliminating windshield scratches from robotic
decking system
- Reduced scrap by $78,000 annually, eliminated rework labor $110,000
- Project resulted in $188,000 annual savings.
. Led Solder Team reducing downtime on Robotic Auto-Solder Cell
- Reduced system downtime by 73%, reducing shifts required to meet
volumes and eliminating manual operation
- Project resulted in $578,000 annual saving
Pilkington - Clinton, Michigan
May 1994 -March 2000
Manufacturing Engineer
. Responsible for maintaining and improving glass manufacturing
processes by increasing throughput, uptime, yield and quality.
. Develop preventive maintenance schedules, trouble shooting guides,
start-up check list and control plans for new and existing equipment.
. Provide equipment and tooling; plan processes; issue instructions; and
set performance standards consistent with quality, quantity, cost,
safety and schedule requirements
. Developed CER for cost reduction projects, source equipment and manage
project to maintain approved budget spending
. Provide Root Cause analysis for equipment or process failures and
implement corrective actions for effective resolution.
. Plan and implement cost improvement projects
. Coordinate the capital budgets for the Manufacturing Group, review
CARs, track project schedules, and prepare project narratives for
budget submission
. Project manager responsibilities includes the following projects:
- CK Doorlites Robotic Prime Cell - CK Doorlite In-Mold Paint System -
330 QW in Mold Painting
- GM200 Robotic Encapsulation Process - Transfer 330 platforms from
Canada plant to Clinton, Plant
- PN 96 Robotic Urethane Cell - GMX130 Robotic Urethane Cell
Skills and Training:
Leading Effective Teams Training Total Productive Maintenance (TPM)
5S/Visual Workplace
Microsoft Word, Excel, and PowerPoint Patent in Robotics
QS 9000 Internal Auditor TPM
Implementation Lean implementation TQM /
Lean Experience
Certified Six Sigma Green Belt
Activities/Honors
Jackson College Excellence in Learning Award 1998; Mott College Deans List:
Fall of 1990, fall 1991, winter of 1992; Mott College High Honors in
Graduating Class
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