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Project Manager Six Sigma

United States
January 31, 2014

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Mark E. Cargill


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

Marina Del Rey, CA 90292




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.


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 -


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


. 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


- 6% yield improvement in residential tile line from one Kaizen


- $789,000 savings elimination TI02 and using opaque film from VSA


- 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


. 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


. 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


. 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


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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