Operations and Engineering Leader

MARK VILCEK **** Fiorellino Place / Cedar Park, TX 78613 / ********@*****.*** / 248-***-****

OPERATIONS AND ENGINEERING LEADER

GENERAL MANAGEMENT / PRODUCT DEVELOPMENT / ORGANIZATIONAL GROWTH

Strategic thinking leader with a steady track record of delivering operational excellence with 20+ years progressive experience

in Production, Supply Chain Management, Lean Manufacturing Engineering, Program Management, Product Engineering, and

Small Business Startup. Innovative and creative engineer drives NPI and Process Development in both mature and high

growth organizations. Industry knowledge includes Engineered Automotive Components, Oil and Gas Technology,

Electronics, Alternative Energy, High Volume Consumer Products, Specialty Chemicals and Plastics, and Military Spec

markets. Achieves margin improvement through recognizing cost reduction opportunities and value added design

enhancements. Creates high performance results through team development, effective direct report leadership, collaboration

all organizational levels, and an effective and influencing communication style.

PROFESSIONAL ACCOMPLISHMENTS

TOLTEQ GROUP - Cedar Park, TX Jan 2014 - Dec 2014 MANAGEMENT

PRODUCTION OPERATIONS MANAGER

Capital Expenditures

Challenge: To develop a lean manufacturing organization to support 100% sales growth and improve

operations based on performance metrics of cost, quality, delivery, and inventory turns Production & QA Management

Actions: Directed a plant re-organization to increase capacity by 50% and staffing plan development for Continuous Process Improvement

potential 2 shift operation.

Business Process Development

Added production, supervisory, quality, and engineering staff (25+ total) to support growth

•

Cross Functional Team

Optimized workflow through balancing work cells and cross training

•

Leadership

Directed supply chain activities to satisfy sales forecast vs. make to order

•

Developed metrics for on-time delivery, quality defects, lead time, and inventory turns

• Team Development

Strategized with senior management, and interfaced with key internal teams to establish and execute

•

Supply Chain

operational objectives, such as Lean Workflow implementation, 5S, and MRP/APS

Results: Q3 & Q4 operating at over 200% increase compared to Q1 & Q2 forecast and actuals Profit & Loss (P&L)

Budgeting

Improved on-time delivery to over 98% for six consecutive months, reduced lead times from 12

•

weeks to the expected 3-4 weeks by driving supply chain to satisfy quarterly sales forecasts

Margin Growth

Improved component first pass yield from low 80% to over 90%, using CAPA process and

•

structured problem solving

Reduced quality escapes from 1/month to 1/quarter after developing and coaching new QC

•

ENGINEERING

specialists team and updating & improving production control documentation

Operational Expenditures held to 90% of budget for FY 2014

• Advanced Product Quality

Inventory turns increased by 65% Planning (APQP)

•

Structured Problem Solving

DYNAMAX INC. - Austin, TX Aug 2012 - Dec 2013

NPI Champion and Contributor

DIRECTOR OF OPERATIONS

Challenge: To develop a professional production organization to support 50% sales growth, reduce COGS Manufacturing Engineering

and increase profitability by 10%+, increase customer satisfaction through improved quality and decreased

Product Lifecycle Management

lead times

Actions: Plant relocation and lean workflow implementation to increase capacity by 100% and staffing plan Design Reviews

development for multi-shift operation.

Program Management

Concurrent decommissioning of old factory, and 2 month commissioning of new plant

•

Failure Mode Analysis

Staff re-organization of 10+ terminations and 20+ hirings (50+ total) to support growth.

•

Capital project implementation to improve safety (zero LTA), quality (internal and external defects) CAD designer/engineer

•

and material yield supervision

Strategized with Senior Management and Board to prepare operating budget, set performance goals,

•

and capital expenditures

Directed product design enhancements and launched 2 new products in 6 months

• STRATEGY

Results: Operational metrics were all trending positively, revenue grew by 175% Sales and Ops Planning

COGS reduction 10%+, from 2012 to 2013, increased turns by 100% Strategic Planning

•

Improved on-time delivery to over 95% for 9 consecutive months, reduced lead times from 6 weeks

•

Goal Setting

to the expected 1-2 weeks by productivity improvements and driving supply chain to satisfy

quarterly sales forecasts Market Evaluation

Improved quality from 5% rejects per week <0.1% per week by implementing SOPs, Quality

•

Customer Requirements

Standards, QC inspection team, and technician proficiency checklists

Operational Expenditures held to 95% of budget for FY 2013

•

MARK VILCEK pg. 2 ********@*****.*** / 248-***-****

PROFESSIONAL ACCOMPLISHMENTS cont.

VIRYD TECHNOLOGIES - Austin, TX Jul 2010 - May 2012

MANUFACTURING OPERATIONS MANAGER / SR. MANUFACTURING ENGINEER

Challenge: To develop and expand manufacturing operations of a wind turbine product range, and Program

Manager of sustaining products TRAINING

Actions: Established lean manufacturing assembly and test processes, visual inventory flow, SOPs, safety and Project Management

quality programs, and managed 8 contract manufacturers in China and North America

Lean Manufacturing Engineering

Staffed and trained a production and engineering technician team of 10 to execute product

•

assembly, quality testing and system integration. APQP

Managed facility infrastructure upgrades including 30,000 sqft building expansion and utility

•

Shainin / Red X Problem Solving

provisions at 15% under budget

Implemented Kaizen events, Kanban, and visual trigger inventory flow and control resulting in

• Six Sigma

cycle time reduction of 50%

Statistical Process Control

Conducted due diligence analysis for acquisition of a contract manufacturer

•

APICS MRP/APS

Results: Implemented process improvements and drove cost reduction resulting in 10% cost savings pre-

launch

ISO 9001

Developed world class assembly and test factory for <10kW wind turbines

•

TS16949

Problem Resolution Tracking System (PRTS) and structured problem solving reduced critical

•

success roadblocks to meet aggressive program timing Unigraphics / AutoCAD

Built 1st unit for installation at Illinois Institute of Technology for part of a joint corporate and

•

Finance for Technical

academic effort to promote alternative energy in the US.

Professionals

OTHER PROFESSIONAL EXPERIENCE* – Lake Orion, MI Jan 2009 – Jun 2010 PLC programming

L&L PRODUCTS – Romeo, MI Process Engineering Technology

ADVANCED ENGINEERING PROGRAM MANAGER May 2006 – Nov 2008

Safety Training Certification

Challenge: To develop and execute North American engineering strategy for structural components in Korean

OEM market Factory Environmental

Compliance

Actions: Established engineering and test team and directed design and mfg. strategy for 3 vehicle platforms

Results: Awarded $9.0MM project on injection molded structural adhesive composite inserts to meet Federal

Safety Standard for Side Impact to reach 5 Star rating on sedan and SUV platforms.

COMPUTER SKILLS

PRODUCT DEVELOPMENT ENGINEER Jun 2001 – Nov 2008 High Microsoft Office Proficiency

Challenge: To engineer and commercialize sealing and structural solutions for automotive and aerospace MS Project & Visio

applications, and increase revenue by 25% through opportunistic selling and creativity

ERP – Syteline, Oracle, SAP

Actions: Directed design, validation team, and manufacturing strategy for 5 vehicle platforms, and

communicated technical and commercial information at all organizational levels including C level, directors, JIRA

engineering and plant managers, purchasing managers, and application engineers

MiniTab

Results: Directed design, testing and implementation over 150 new product designs on eight different vehicle

platforms generating cumulative revenues of over $50MM, consistently growing vehicle content by 20%

Holder of 2 patents generating annual revenues over $6.0MM

•

RECOGNITIONS

SR. MANUFACTURING ENGINEER Small Business Development

Oct 1998 – May 2001

Certification – University of TX

Commissioned 4 new manufacturing lines / processes using lean manufacturing philosophy,

•

including equipment selection, installation, and pre-production validation Patent #200******** -

Increased first pass yield from 85% to 97% by implementing SPC control charting and process Automotive Roof Ditch Joint

•

optimization procedures for twin screw extrusion lines Sealant

Managed efforts of cross-functional groups to integrate and debug new process startups. 3

•

Patent #200******** – Noise

successful product launches in 2 years, yielding sales of approximately $10MM combined

Reduction System

UNILEVER CORP. - Chicago, IL & Hammond, IN

SR. PROJECT ENGINEER 1995 - 1998

*OTHER PROFESSIONAL

PRODUCTION ENGINEER/SUPERVISOR 1991 - 1995

EXPERIENCE

Direct Marketing / Sales

EDUCATION

Professional – 4 yrs

B.S. INDUSTRIAL AND SYSTEMS ENTERPRISE ENGINEERING, minor in Business Administration

UNIVERSITY OF ILLINOIS AT URBANA / CHAMPAIGN Private Business Owner – 3 yrs

M.B.A. coursework completed in Marketing, Finance, Organizational Management, Manufacturer’s Rep. - 1 yr

International Business, Business Law

UNIVERSITY OF PHOENIX

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