Engineer Six Sigma

Fred Ayres

Certified Six Sigma Black Belt

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

West Plains, MO 65775

Home Phone: 417-***-****

Cellular: 815-***-****

E-Mail: ************@*****.***

Work Experience

Regal Beloit Corp

West Plains, Mo

Title: Continuous Improvement Manager (Sept 2012-Nov 14, 2014)

Trained 30 Yellow Belts-Certified 11

Certified 4 Green Belts-Mentored 9

Conducted Monthly Kaizen Events (16)

Operational Excellence Auditor

5S Auditor

Completed Regal Beloit Green & Black Belt Training

Terminated Under “Reduction In Workforce”

Dana Corp

Columbia, MO (June 2007-July 2008)

Title: Six Sigma Black Belt

Responsibilities:

• Process Improvement Projects

• Participate IN MTB Groups(Making Things Better)

Completed 6 Projects $713,250 Hard & Soft Savings

1) Changed delivery time on several critical to quality shims from 16 weeks to 6 weeks.

Coordinated with IT to develop a usage tracking methodology instead of doing a

inventory count manually.$30K Hard Savings-$550K Soft Savings

2) Relocated andon lights on machining cells, added work stoppage buzzers, and

increased feed rate on drilling operations. $63K savings

3) Redesigned transfer device and conveyor. Eliminated 1 temporary worker. $35K Savings.

4) Excess glove usage-Reduced monthly usage from 1370 dozen gloves to 850 dozen. $15K

Savings

5) Eliminated stripping of cover plate holes. $9500 Savings

6) Stripping Issues. $10,750 Savings

Accument/Textron

Rockford, IL (2003-October 2006)

Title: Six Sigma Black Belt-$505K Total Savings

Responsibilities:

• Mentored (7) Green Belts

1

• Lead or Supported Kaizen Events (7)

• Supported GB Training

• Process Improvement Projects:

Evaluated and purchased equipment for a manufacturing cell in order to meet increased

1)

sales demand. $395K Savings

Developed POKE Yoke to stop product from feeding down rails when defective from

2)

previous operation. 67K Savings

Elimination of sort on 0-15PPM parts. 43% reduction in number of parts sorted. $43K

3)

Savings.

Developed the first Kanban system at Rochester, IN facility where I was the lead Black

4)

Belt.

Was told by current plant manager at Rochester, IN facility that my Kaizen event in pre-

5)

sorting area was the best Six Sigma project held there.

Textron/Elco

Rockford, IL (August 1979-2003)

Title: Fastener Engineer

Responsibilities: Designed Tooling Used In Fastener Production

• Detail & Assembly Drawings

• Progression & Production Drawings

• Resolved Manufacturing Floor Quality Issues

Completed Track 1 & Track II Leadership Training

Completed Tool Design I & II at National Machinery-Tiffin, Ohio

Advanced From Entry Level to Sr. Process Engineer

Education

**ED2GO**

AutoCAD 2011/AutoCAD 3D

230 Training Hours

Start Date (4/09/2012)

Columbia Regional Training Center

Advanced Word Completed November 29, 2011

Columbia Area Career Center- Columbia, MO

Introduction to Networking Completed November 28, 2011

Introduction to Java Programming Completed September 2, 2011

Introduction to PC Troubleshooting Completed June 26, 2011

2

Distribution & Logistics Management Completed April 25, 2011

Introduction to Visual Management Completed March 2, 2011

Introduction to XHMTL & CSS Completed December 19, 2010

Creating Web Pages Completed November 29, 2010

Introduction to Oracle Completed October 11, 2010

Introduction to Data Base Dev. Completed September 24, 2010

Introduction to SQL Completed August 27, 2010

Intermediate Microsoft Access 2007 Completed July 23, 2010

Introduction to Microsoft Access 2007 Completed May 28, 2010

Johnson County Community College-Overland Park, KS

Certificate- Purchasing and Supply Chain Management

300 HR. Online Program-Completed (April 2010)

Cardinal Stritch University-Milwaukee, WI

BS Management (5/18/2003)

Graduated with Academic Distinction

Northern Illinois University-Dekalb, IL

General Studies-18 Credit Hours

Rock Valley College-Rockford, IL

Solidworks

Sauk Valley College-Dixon, IL

AAS Mechanical Design

Graduated with Honors

Additional Key Accomplishments

Certified Shainin Red X-Apprentice Level (August 2008)

Certified as Textron DFSS Black Belt (August 2005)

Worked in Japanese Joint Venture (1989) Learned to Speak and Read Basic Japanese

Lean & Six Sigma Tools Used:

7 Waste, Value Stream Mapping, Takt Time, 5S, 5 Why, Kanban, SMED, Visual Management,

Poke Yoke, Single Piece Flow, FMEA, Ishikawa Diagram, Hypothesis Testing, Process

Capability, Process Flow Charts, HOQ, TRIZ, Pareto, ….

Other Tools:

• Cadra Drafting System

3

• DR. Forging

• Deform-Basic Finite Element Training

• Solidworks

• Microsoft Tools

4

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