Manager Management

Dear Human Resources,

I am writing to submit my qualifications and experience for consideration for your Continuous

Improvement Manager.

I have several years experience leading Kaizens and training teams for lean / continuous

improvements in operations and maintenance organizations. While working with the teams, I

have experience establishing team meeting ground rules and roles, stepping through and training

on identifying cost / product variations, brainstorming ideas for improvements, testing the ideas,

managing implementation of approved capital improvement projects and follow up with

stakeholders to ensure objectives are met.

My experience also includes implementing and training lean manufacturing practices. I spend a

majority of my time on the factory floor discussing with the operators ideas for improvement and

ways to look for and eliminate waste. I enjoy these activities as I bring engineering and six sigma

analysis tools and work with operations management and operators on how to use them for

improvements.

My hands on management experience includes Engineering, Maintenance and Operations at

multiple sites. This provides broad experience leading technical resources developing

manufacturing layouts, defining and measuring equipment capabilities, designing and

implementing automated, high speed and manual production equipment. With my experience of

managing and implementing a wide range of projects, I bring the skills to develop realistic project

plans, including resource needs and accurate budgets.

I have very strong automation skills and perform the design and software development on

projects which provides automated data collection of operational activity which is used to

objectivity measure before and after results to verify improvements. Also the data is utilized in

visual Factory scoreboards, communicating real time operational activity information.

I have experience with new product launches and their implementations into existing facilities,

including manufacturing equipment development, process capabilities and employee training.

I have Lean Six Sigma Black Belt certification and strong data analysis skills along with team

facilitation training. Continuous improvement with team involvement is rewarding for me

personally as well as beneficial to the employees and business.

Please consider me as a candidate for your Continuous Improvement Manager position. The

responsibilities are rewarding for me in the opportunity to learn, teach and improve existing

processes. I can be reached at **************@***.*** or 336-***-****.

Regards,

Todd Yarborough

TODD M. YARBOROUGH

**************@***.*** 3006 Scout Trail

336-***-**** (home) 336-***-**** (cell) Jamestown, NC 27282

EXECUTIVE SUMMARY

Results oriented Engineering and Facilities Management professional with Lean Six Sigma Black Belt certification.

Experience leading continuous improvement teams, managing improvement projects including capital justification,

design, installation, equipment validation and employee training. Successful track record of facilitating innovative

process improvements, business cost reductions through productivity and quality improvement. Known for innovation, a

strong customer focus and an enthusiastic, hands-on approach to solving complex problems in multi-disciplined, multi-

cultural environments. Possess strong communication skills, frequently presenting complicated material to all levels of

the organization including executive management.

SKILLS

• •

Continuous Improvement – Certified Lean Six Safety and Environmental regulations for

Sigma Black Belt manufacturing

• •

Management of Engineering, Maintenance and Team Building, Facilitation and Training,

Operations Organization Development

• •

Management of Expense, Capital projects and Equipment Automation Development

budgets

• •

Capital Asset Maintenance Data Driven Problem Solver

PROFESSIONAL EXPERIENCE

Endura Products, Colfax, NC (www.enduraproducts.com) Plant Engineering Manager 2014 – Present

(Door and Engineered Components Company)

• Reduced wood business downtime ~ 30% utilizing lean six sigma tools to identify and eliminate root causes.

• Developed layout and material flow improvements through Kaizen and Value Stream Mapping events.

• Developed and presented capital cost justifications using as-is / to-be modifications.

• Improved equipment OEE ~23% through time studies and hands on equipment operation.

• Defined relevant KPIs for analysis and used to identify opportunity for improvement and monitor results.

• Manage Engineering, Maintenance, Environmental, facility support personnel and external contractors for capital

projects, facility modifications and day to day activities for multiple sites.

• Led maintenance department culture change, improving equipment uptime, implemented predictive maintenance,

established reporting providing transparency of maintenance and support functions’ activities.

• Manage multiple departments’ capital projects and budgets, including maintenance and utility expenses.

• Established engineering and maintenance structure, including accountability and activity tracking.

• Developed training plans for skills gaps, talent retention and growth to meet current and future business needs.

• Engineering lead for new business and equipment evaluations.

Vertellus Specialties, Greensboro, NC (www.vertellus.com) Engineering/ Facilities Manager 2006 – 2014

(Global Chemical Specialties Company – including FDA regulated excipients)

• Management responsibilities include directing Engineering, Maintenance, facility support personnel and external

contractors for capital projects, facility modifications and day to day activities. Lead progress reporting meetings.

• Establish and adhere to multiple department budgets including capital projects and operational expenses.

• Manage external contractors, support contracts and site safety training program for contractors.

• Manage equipment validations, equipment calibrations and support to maintain ISO registration.

• Manage site Lean incentives for productivity gains through facility, equipment and automation modifications.

• Facility and Equipment technical advisor for evaluation and implementation of business acquisitions and growth.

• Prepare and present (monthly) to site employees progress toward site goals, capital projects progress and energy

costs.

• Prepare and maintain site emergency response and business interruption prevention plan.

• Manage Facility Utility Costs Reductions. Achieved 5% annual reductions (significant for chemical plant).

• Manage implementation of technologies for automated chemical manufacturing, providing electronic process

data.

• Introduced new reactor cleaning technology, reducing cleaning durations from 30 hours to 4 hours, providing

additional 20% plant capacity, resulting in reducing manufacturing schedule from 7 days per week to 5 days per week.

Banner Pharmacaps, High Point, NC. (www.banpharm.com) Sr-Manager, Global Operations Systems 1995 - 2005

(Global company, manufacturer of pharmaceutical, over the counter and nutritional soflet® and sofgel products.)

Duties include strategic planning, innovation, project management, capital procurement, global deployment, system

security and administration of progressive business improvement solutions. Develop / implement business process

software using multiple software products, specify hardware for automated equipment and associated computer systems.

Develop / implement employee training programs regarding continuous improvement and computerized systems.

Perform design, fabrication, validation, documentation, implementation and commissioning of automated systems,

equipment and procedures, ensuring cGMP compliance and meeting FDA regulations.

• Managed organizational development of core manufacturing operation, increasing product yields from 91% to 98%,

machine uptime to 21 hours/day, in a high mix environment, utilizing 5S, Flow Path Management, and Kaizen events.

• Managed product cost reduction teams utilizing Kaizen events, reducing the product manufacturing costs 17%.

• Managed waste reduction program, achieved product cost reduction of 4% annually.

• Managed cross-functional process improvement teams, implementing new production methods and equipment.

• Managed Post Production Operations department, $12MM budget, 7 direct reports and 180 indirect reports.

• Developed automated systems to capture and report real-time manufacturing data providing root cause analysis,

statistical process control (SPC), process capability and capacity assessments for the overall operation.

• Developed and administered key performance indicator (KPI) automated systems, providing overall equipment

effectiveness (OEE), product throughput and manufacturing cycle time.

• Developed computerized process simulations and identified greatest productivity gains with minimum risk. Used

simulations to investigate “what if” scenarios, determined costs and return on investment (ROI).

• Developed, implemented, trained personnel for operation and administered the world’s most advanced automated

capsule testing system utilizing electronic signatures complying with 21 CFR Part 11, featured in press releases,

eliminated paper recording, reduced process errors and revealed manufacturing low risk-high improvement

opportunities.

• Developed and administered world’s most advanced automated gel mass manufacturing system, managed / performed

all system software / hardware changes, performed validation, wrote system standard operating procedures (SOPs),

developed and implemented training programs.

• Key contributor in meeting pharmaceutical facility plant start-up schedule and budget.

Project Manager, National Technologies Group, Raleigh, NC (Consulting Company) 1994 -

1995

Duties included strategic planning, managing, tracking, reporting of office automation (hardware & software) projects.

• Managed systems engineers whose responsibilities included personal computer configuration, field installation, and

hardware/software problem resolution, managed project coordination personnel whose duties included tracking,

scheduling and follow up of delivery and installation.

• Initiated and facilitated process flow analysis improvements that reduced labor costs 35%, increased department

revenue 40% and obtained a cycle time reduction of 30%.

EDUCATION

University of North Carolina Charlotte, Bachelor of Science Electrical Engineering (BSEE)

Cooperative Education Program, experienced nuclear power plant start-up, personally provided 100% finance.

Wingate University, Associate in Science - Awarded Eastman Kodak Scholarship, VP of Engineering Society

FORMAL TRAINING

Lean Manufacturing / Process / Productivity Improvement Tools (Kaizen, Kanban, 5S, Flow Path Management (FPM),

Pull Scheduling, CONWIP)

Process Modeling (develop computerized simulations of business processes), Statistical Process Control (SPC)

Total Quality Management (TQM), Continuous Quality Improvement (CQI) methods

Presenting for results, Effective communication, Understanding people, Team Leadership Essentials, Coaching Skills

Assertiveness Skills for Managers and Supervisors

Kepner-Trego Problem solving and Decision making, Team Building and Facilitation, Project Management

Computer Validation for pharmaceutical industries, 21 CFR Part 11, Electronic Records, Electronic Signatures

SOFTWARE COMPETENCIES

Minitab statistical software, Microsoft Project, Microsoft Access, All Microsoft Operating Systems, Database

Architecture, Microsoft Networking, SAP, MRP, various database applications

Microsoft Office Professional software application development, strong knowledge of Microsoft Office products.

ProcessModel (develop computerized simulations of business and manufacturing processes)

Visual Basic (VB6), Visual Basic for Applications (VBA), SQL, Visio Technical (2-D Drawing Package)

Multiple Allen Bradley PLC programming languages, RSView Human Machine Interface (HMI) application

development, 18years experience GE Fanuc Intellution SCADA (HMI) products

Contact this candidate