Six Sigma Engineer

Rick A. Duncan

**** ******* ***** **** **** Chester, Ohio 45069-1567 513-***-****

mobile

*********@*****.***

Education :

BS Industrial Engineering, North Carolina State University 1981

Qualifications :

I have trained under two Japanese Senseis in the Lean techniques of the

Toyota Production System (TPS) and worked with an American Sensei. Using

this knowledge base, I have conducted Lean training from the shop floor to

the boardroom and led multiple Continuous Improvement events in production,

accounting, and the supply chain. ROI's have typically been greater than

$1,000,000 per year. Clients have included the personnel from the USAF,

automotive industry, pharmaceutical industry, and food industries.

Lean Training Specialist Industrial Engineer Six Sigma

Black Belt

Value Stream Mapping Labor Standards / SAP DMAIC methodology

Kaizen events Line balancing

Thought maps

Kanban/Pull systems Cellular design Process mapping

One Piece Flow Ergonomics 5S/Work Place

Process Design Floor layout / AutoCAD FMEA

Run/control charts Visual Management TPM

Standardized work SMED/QCO Risk analysis

Achievements :

. 60% compression of start-up time for packaging line

. Development of Lean training modules and manuals for plant wide use

. $5.6 million cost avoidance through 16% material yield improvement in

packaging.

. $5M+ projected savings through rework reduction, Standard Work, and TPM

for Air Force MRO department

. 28% productivity improvement in two months for $300K savings by work

balancing assembly cells with standardized work for ABS braking units.

. $720K savings in two week redesign of machining cell flow with a 9 heads

reduced.

. 30% improvement is scheduling optimization of shipping, receiving, and

load optimization in dock usage

. $2.31M benefit from a capital equipment project that reduced thirteen

heads in tool regrinding with cost justification on CNC equipment.

. $480K improvement by designing and implementing an inventory control and

supply system in two months for clean room assembly cells.

. $200K savings by developing plant wide down time tracking system.

. $257K improvement by reconfiguring machining line in thermal deburr

operation.

Professional:

Institute of Industrial Engineers - professional member

Six Sigma Black Belt certification - 2010

IIE Dayton Chapter former secretary - 2009-2014

Published - Learning to see. . . again, Institute of Industrial Engineers

website May 2010

Published - Giving Structure to Lean Learning, IIE Lean Division Newsletter

June 2009

Operational Excellence Conference, speaker 2008 - "Understanding Lean

Visions"

IIE Outstanding Service Award - 2007

Published - USAF Depot Maintenance, Changing Paces with Lean, IIE Lean

Division Newsletter May 2005

Experience :

Incito Consulting Group, LLC April 2011 - July 2014

Deployed Lean initiatives across several facilities. Have worked with food

manufacturing industries, established an estimated $1,000,000 per year

savings with the following techniques: Value Stream Mapping, Total

Productive Maintenance (TPM), developed Pull Systems, Line Balancing,

Theory of Constraints (TOC), Standard Work documentation and SOP's,

Process Mapping, Visual Management, structured Kamishibai with Leader

Standard Work and Gemba. Structured a Lean applications and training system

for the clients for both production and maintenance personel. Developed

Lean Training modules for SME's, CIL's, and management personel. Systems

are designed to develop and mature associate level abilities so that

responsibilities can be turned over to the client personnel. Managed field

teams at customer sites.

Heartwood Consulting, LLC

Established a consulting business to work with management in the

development of their Lean applications and training. Training modules are

designed to cover Lean implementation by company associates. Customers

include the food manufacturing, wood working, pharmaceuticals, and

automotive industries. Have worked with other consulting groups on an as

needed bases. 1988 - present

Lean Process Engineer: Amylin Ohio LLC

As an internal consultant, taught and led Lean process improvements

initiatives focusing on reduction of materials and labor in operations

supporting the main production batch process flow. Areas of execution

include Value Stream Mapping entire local process at mid-level, 5S in

laboratories and engineering, and maintenance areas, POU materials, supply

chain improvements, and Lean training. Developed Leadership Team training

and exercises for understanding Lean and Six Sigma methodologies. Developed

standard work definitions through Motion Kaizan for 'Gen II' fill,

assembly, and packaging line. Set up packaging line balancing and materials

flow, 1/2008 - 7/8/2010.

Lean Facilitator/Senior Industrial Engineer: Concurrent Technologies Corp.

Lead rework reduction project as an internal consultant, with efforts

focused on standardized work, Six Sigma efforts, and Total Productive

maintenance. As a lean consultant/facilitator contracted to the USAF HQ

AFMC for the three aircraft maintenance depots, I have taught lessons in

5S, Work Place Design, Cellular Principles, Single Minute Exchange of Dies

(SMED)/Quick Change Over, Value Stream Mapping (VSM), lead Kaizen events,

and Practical Problem Solving (PPS) sessions. 12/2003 - 12/2007.

Industrial Engineering, Delphi Automotive Systems

$5.4M savings through Continuous Improvement Projects over five years in

industrial engineering for automotive manufacturing plants in Anti-lock

Braking Systems, Master Cylinders, Disc Shoe & Lining, and Tool regrind.

Developed shipping/receiving window schedule board system with loading

procedures to facilitate materials flow at docks. Provided leadership for

cell layout, standardized work, lean process flow, and cost and methods

analysis. Obtained Six Sigma Green Belt certification. 7/1998 - 12/2003

Production Supervisor, Sachi Woodworking Inc.

Supervised the wood finishing operations for an architectural woodworking

facility providing high-end architectural building materials. Responsible

for production scheduling and control, quality control, specify materials

and equipment requirements, and color matching to customer specifications.

7/1997 - 7/1998

Heartwood Consulting, Inc.

Managed company providing specialized services and consulting to the

construction industry and wood working industry. Responsible for sales,

planning, estimating, purchasing, supervision, OHSA compliance, and

bookkeeping. 1988 - 2014

Industrial / Plant Engineering, Kabinart Corp.

Provided engineering management services for a manufacturing facility with

$ 12 million in annual revenues and employing 110 people. Supervised plant

maintenance department while providing engineering support to production

operations. 1987 - 1988

Industrial Engineering, Campbell & Dann Manufacturing Co.

Production scheduling and control, estimation, inventory control, labor

standards and employee incentive systems for this company with 45 employees

and $3 million in annual revenues. 1983 - 1987

Production Supervisor, Ranch Redwood Co.

Oversaw a seven-man crew with responsibilities for machine setup,

production throughput, and maintenance of equipment. 1982 - 1983

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