Manager Engineer

Daryl J. Balcom

**** **** **** *****, ***********, IL 60440 (H) 630-***-**** – (C) 630-***-**** ********@*****.***

SUMMARY OF SKILLS:

My goal is to secure a position as a Quality Manager with growth opportunity to Plant Manager or Site Leader

Inspirational leader who sets personal example and drives discipline culture

M.S. in Engineering Management and B.S. in Computer Engineering

18+ years of leadership and management experience

Program Manager for diverse computer, security, R&D, and financial programs

Established briefer, effective communicator, and skillful writer

ASQ Six Sigma Black Belt Certification Course, Green Belt Certification

SQF Practitioner, ISO Management Rep, RABQSA Certified ISO Internal Auditor, Lean Manufacturing

Professional Management skills include ability to plan, budget, and execute complex technical projects

Dedicated team player, incredible attention to detail, and strong organizational skills

Quality Assurance Management, Continuous Improvement, DMAIC, 5S, SMED, kaizen, food grade dairy packaging, corporate quality KPI development, metrics development and analysis integrating multiple software applications to drive process improvement initiatives, customer and supplier relations, Minitab, SPC Lighthouse, GMP, HACCP, CAPA, Nonconformance management, supplier quality management, JDE, SAP, Cognos, WebEFF, Polar, calibration, gauging, thermoforming and injection molding process control, dry-offset printing and indirect flexograph printing experience, expert user of MS Office applications, Visual Basic, C++, SQL, Assembly Language, VHDL, XML, HTML, CircuitMaker, PROSIM, KV Ladder, PC Board Design, and using/maintaining electronics

Continuous Improvement Manager Pamco Label Company, Des Plaines, IL May 2014 - Present

Responsible for establishing and maintaining Quality Assurance standards and procedures that improve and enhance company's ability to consistently meet customer's needs and expectations.

Introduce, train, and coach use of Lean Manufacturing and Six Sigma Quality tools such as FMEA, SPC, 8-D, 5-Why, RC/CA, and 5S.

Developed and implemented a RC/CA automated system for the evaluation of non-conformances including: investigation, evaluation, review, reporting, and responding to customers both internal and external. The system allows us to trend and analyze data in order to focus on areas of biggest opportunity and verify the overall effectiveness of corrective action implementation.

Responsible for establishing an ISO-9001 compliant Quality Management system with the goal of obtaining certification

Core Team member of implementing a company wide (more than 6 plants) ERP transition

Quality Manager Pentair Filtration & Process, Hanover Park, IL Jan 2014 – May 2014

Customer Relationship and Supplier Performance Management – Reduced RC/CA response from 120+ days to less than 5

Internal Scrap reduction from $1,000/day to $700/day – projected $93,600 annual savings

Facilitate and mentor Creating Continuous Flow Workshop – reduce cost 82%, increase productivity 39% and decreased earned hours 31%

Streamlined Quality metric reporting – saved over 1hr/day of technician time

Provide leadership for the quality team in the resolution of problems and continuous improvement of product, processes and QMS

Integrate the Voice of the Customer to actionable manufacturing and supplier strategies

Strategy development and deployment focused on clear understanding of legal and regulatory factors, market forces, industry trends, technology trends and competitive pressures - S.W.O.T. (strengths, weaknesses, opportunities, and threats)

Facilitate and promote problem-solving tools (the seven quality control tools, the seven management and planning tools, root cause analysis, Plan-Do-Check-Act (PDCA), 8D, 8 Step Problems Solving, A3, and other like models)

Facilitate and promote process management / lean manufacturing approaches with a quality principled focus

Continuous Improvement Manager Berry Plastics Corporation, Alsip, IL Feb 2011 – Jan 2014

Maintain ISO and SQF Certifications –SQF Level 3 Initial Certification Audit score of 98; 2013 Surveillance Audit Score of 99

Customer complaint reduction and process improvement focus across the facility – 18% reduction year over year

Provide skill development opportunities for all quality employees through training – SPC, Gauge R&R, Six Sigma, Excel, and statistics

Provide analytical data to assist process improvements in all departments – Scrap, Defect, Efficiency, Downtime

Drive Continuous improvement of process and Quality procedures

Mentor and Develop Quality Leadership throughout division of 13 plants

Work closely with demanding customer base to exceed expectations.

Designed, developed and implemented corporate-wide production tracking, complaint analysis, and tooling first time pass rate

Quality Assurance Engineer Berry Plastics Corporation, Alsip, IL May 2010 – Feb 2011

Responsible for 500+ gauge calibration program, Sanitation Program, Gauge R&R’s, and data track and trending for SQF Validation

Developed operator driven quality concept and implemented in 3 manufacturing departments – reduced defects 32%

SPC Data Track & Trending for Division implementation (13 plants) – recovered 4 hrs/wk of work for QA personnel

Design, developed, and implemented automated Efficiency Trending Charts from Web-based data entry system

oImplemented company wide – focus on quicker RC/CA analysis and standardization

Member of 5S, ISO, Gung Ho, Scrap, Heldware, and SMED Plant Teams

Master Planner / Scheduler / Buyer Honeywell – Prestone, Alsip, IL November 2009 – May 2010

Maintain SAP data integrity – BOMs, production planning, ordering, shipping, receiving, and inventory

Responsible for planning production for multiple production lines with over 150 SKU’s – on time to request of 96.4%

Place purchase orders, monitor and maintain scheduling agreements for all raw materials supporting production schedule

Daryl J. Balcom

Continuously evaluate lower cost suppliers for locally negotiated materials – over $100K annual savings

Lowered inventory by implementing Kanban and pull systems for over 60% of commodities

Update weekly delivery/quality metrics for one plant and 3 distribution centers

Conduct daily cycle counts and reconcile variances in SAP

Conduct quarterly Physical Inventory – 4Q 09 result was 99.5% accuracy

Process, Project, and Quality Engineer Honeywell – Prestone, Alsip, IL April 2007 – November 2009

ISO/TS16949 Internal Auditor Certification

Maintain & improve the ISO-9001/TS16949 Quality System

Support Prestone initiatives (Honeywell Operating System (HOS), Lean Management System, and SAP implementation)

Host internal and external quality audits (supplier, corporate, and TS16949)

Directs employees as it relates to adherence to corporate and plant quality programs, policy, procedures, and specification

Supervise quality technician, Lead 5S auditing program, drive kaizens, rapid problem solving, standard work, and maintain SPC database software/programs

Led team in waste reduction – 2 month effort resulted in process improvements realizing $35K, $100K expected annually

oUsed Green Belt Six Sigma Tools, planned for 6 months, no capital investment, 2 months to implement

Changeover flexibility team lead – 12 month effort resulted in single month savings over $53K, $280K annual goal

oNow capable of switching out blowmolding molds – additional improvements refined 16 hour change to 2 hours

Led Internal ppm defect reduction team to 20% fewer defects in 2008 versus 2007 while reducing WIP

oEnhanced technology to detect potential defect within process – 4500 ppm/month in 2007, average of 3500 in 2008

Key team member in effort to improve OEE% for filling operations – process changes resulted in 7% OEE improvement

oDesigned/implemented photo eyes for data capture, pareto defects, eliminated top defect – 76% OEE to 83% OEE

Blending flexibility team lead – designed and implemented new blending concept to improve plant batching flexibility

oResponsible for concept through implementation – eliminated downtime, increased capability, reduced batch time

Responsible for plant-wide cardboard scrap reduction effort – planned savings of $38K annually

Handpicked by management to lead, coach, and mentor HOS behaviors to shape strategic business initiatives

Electronic Warfare Branch Chief Lackland Air Force Base, San Antonio, TX May 2006 – June 2007

Responsible for the performance of Electronic Warfare projects with respect to cost, schedule and performance

Direct of all phases of projects from inception through completion

Assistant Professor of Aerospace Studies Illinois Institute of Technology, Chicago, IL April 2003 – May 2006

Unit Inspection Officer – Organizational Excellence Award received as a result of annual unit inspections

Recommended for senior staff and rated as a top training instructor at AFROTC field training

Instructed multiple senior level college courses on National Security Affairs and Leadership Studies

Executive Officer Hanscom Air Force Base, Bedford, MA March 2002 – April 2003

Program Manager for $2.3M Information Technology Services Program (ITSP) contract for mission support; conducted requirement evaluation, market research, and proposal evaluation to award contract in just 2 months

Trained 27 personnel on current T&E procedures improving compliance by 35%

Led T&E team providing guidance to ESC’s acquisition programs delivering capabilities to users 20% faster – effort commended by AF Materiel Command

Test and Evaluation Branch Chief Hanscom Air Force Base, Bedford, MA December 2000 – March 2002

Established milestones for programs, monitored adherence to schedule, identified program problems and developed solutions to maintain program schedule

Streamlined schedule and increased test strategy feasibility for $300M integrated maintenance data system, $50M finance replacement system, $40M patient evacuation system, and a program for automating test strategy development

Recognized by the Secretary of the Air Force for Acquisition for managing the Air Force Scientist & Engineer Requirements Review for ESC

Project Manager and System Engineer Los Angeles Air Force Base, CA December 1997 – December 2000

Managed 20 engineers acquiring a $3B national-priority secure, survivable, satellite communication system. Led assessment of system design against operational requirements. Security officer responsible for maintaining all classified data, documentation, and procedures. Led team supporting a Request for Proposal of the $45M requirements phase.

Participated in the negotiation of government contracts and contract changes through source selection activities

Coordinated government proposals, business plans, proposal work statements and spearheaded development of technical specification based on key performance criteria and operational requirements.

Secured $3B contract award for dormant environmental assessment program

Saved over $100K, maintained program schedule, and organized development of Communications Security subsystems

Streamlined process to support three competing contractors and 10 major organizations into a single unified National Team positively impacting 300+ people

Expertly synthesized over 450 technical requirements and achieved 18 month launch acceleration

Primary customer contact for program activities, leads program review sessions to discuss cost, schedule, and technical performance

Lead system engineer for two $60M risk reduction effort programs; on schedule and under budget

EDUCATION:

MS Engineering Management 2003

Syracuse University

gpa: 3.95/4.0

BS Computer Engineering 1997

Penn State and Syracuse University

gpa: 3.36/4.0

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