Manager Engineering, Manufacturing, Production Operations
Resume:
Douglas R. Cokely
*** **** ****, ********, ************* 01835
****.******@*****.***
http://www.linkedin.com/in/dougcokely
Manufacturing and electronics industry Senior Engineering and Operations Executive with emphasis on consistently exceeding KPIs for aggressive new product introductions, rapid expansion, outsourcing, process re-engineering, inter- and intra-company partnerships, customer satisfaction, supply chain and quality improvement. Proven leadership of technical and operations personnel ranging from a 6-person start-up through 120-person three-shift operations. Recruited to lead numerous engineering & production teams to maximize key performance indicators for multiple business-critical product launches and special projects including the Malcolm Baldrige National Quality Award, implementation of Activity Based Costing and introduction of Micro-Interconnect Technology. Pursing senior level operations / engineering position. Expertise includes:
Revenue & Inventory Optimization
Resolution of Technical & Manufacturing Issues
Subcontractor & Supplier Management
Strategic & Operational Planning
NPI & Lifecycle Management
Optical Assembly, Electro-Mechanical Assembly
Lean Process Improvement (Yield, Productivity, On Time Delivery)
Generation & Improvement of Manufacturing Metrics
Experience
GENERAL SCANNING GROUP - Re-Organization, References Available 2013 - 2014
Operations & Manufacturing Engineering Manager
Implement continuous improvement projects, cellular manufacturing, improve documentation & training. Co-host customer quality audits, respond to findings. Lead 115 associates, supervisors and mfg. engineers in production and RMA operations spanning multiple beam steering product lines in $330M mixed volume enterprise to meet 2014 objectives: key product yield improved 86% to 93%; total returns inventory reduced 31%; On-Time Delivery improved 10 points; Past Due 7 to 2 days. Products served medical device, commercial and industrial customers.
ALCATEL-LUCENT / LUCENT TECHNOLOGIES / AT&T – Corporate Restructuring 1990 - 2012
ALCATEL-LUCENT TECHNOLOGIES
Hardware Supply Chain Senior Manager/Director
2008 – 2012
Reporting to the General Manager (North Andover) and subsequently to the North American Senior Supply Chain Director (Plano, TX), optimized business operational performance for 7 product lines sourced internationally and having $300M of annual output (price). Working cross-functionally, maintained supply continuity through international technology transfers, new product introductions, end of life challenges and natural disasters.
Successfully partnered across internal and external organizations to meet or exceed Key Performance Indicators for circuit packs, optical devices and wired equipment deployed to major customers.
Sustained results: quality (1 formal design issue), revenue (98-100+% achieved), on-time delivery (85-95% line basis), strategic inventory (cut 60% in last 24 months).
Drove study to assess realistic options for North American consolidation of software production & distribution facilities, processes, materials and systems - integration completed 2010.
Process Engineering & Operations Senior Manager
2006 - 2008
Led process & quality engineering teams to improve processes and customer responsiveness to new and repair service orders. Managed buyers of custom optical devices and wired equipment.
Ensured 100% compliance with unannounced UL and CSA audits.
Drove cross-organizational compliance with 5-day initial & 10-day final FMA responses.
Led software supply chain team to optimize timely, fiscally & legally responsible deployment of ~400 orderable items replicated to various media types or internally & externally developed license keys.
Balanced customer satisfaction and inventory in a highly unpredictable demand environment.
Douglas R. Cokely Page 2
LUCENT TECHNOLOGIES (Acquired by Alcatel-Lucent)
Process Engineering & Operations Manager
2003 – 2006
Drove process engineering and 3-shift operations teams at North Andover Works to achieve substantial electro-mechanical-optical hardware and software manufacturing improvements. Delivered numerous multi-million dollar trial systems to international customer sites on time.
30% cycle time reduction by implementing visual queues, improved utilization of batch processing facilities, pull techniques, repair management, creation of assessment reports and formal reviews.
Identified software process improvement opportunities to increase on-time delivery by 4 points in 2007; consistently exceeded 95% thereafter.
Zero software customer quality issues in 5 years
LUCENT TECHNOLOGIES (Acquired by Alcatel-Lucent) –continued
Manufacturing Engineering Manager
1997 – 2003
Led Project, Product, Process & Test Engineering new product introduction & volume ramp of a major product developed by an international team and deployed in the Asia Pacific Region. Subsequently executed a manufacturing technology transfer.
Introduced 22 circuit packs & wired equipment on time in a record 8 months. Two additional releases were subsequently introduced on time.
Managed product lifecycle: NPI planning, models manufacture, low and high volume production, new design phase in/out, ICT, Functional & Systems test set design & development, and field return support. Hosted more than 30 successful telecommunications systems validations.
AT&T
Manufacturing Engineering Manager
1995 – 1997
Led technical team NPI & preliminary ramp of a new platform pending parallel introduction of cost effective unit.
Introduced production of pre-optimized design to be first to market.
Manufacturing Business Unit Head
1993 - 1994
Recruited by the Global Business Communications Systems Technical Director to introduce a silicon-on-silicon, Micro Interconnect application to increase competitiveness of commodity products (start-up within a factory). Established process controls, costing models, documentation. Launched production prior to Company selling Intellectual Property.
Partnered with Bell Laboratories materials developers to adapt facilities & introduce new processes.
Component count reduced 33%; end product footprint reduced 30%.
Micro-Electronics Engineering & Manufacturing Manager
1990 - 1993
Promoted to lead hybrid integrated circuit technical and production operations team (bonding silicon integrated circuits to ceramic film integrated circuits). Managed 120+/- production associates and 15 Product and Test engineers to maximize customer service, revenue and cost improvement in thin film business.
Implemented activity-based costing for $200M Hybrid Integrated Circuit manufacturing organization
Education
MBA – Boston University, Boston MA.
MS-ME – Brigham Young University, Provo UT.
BS-ME: Manufacturing Concentration – University of Massachusetts at Amherst.
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Skills
Certifications: ASQ Lean Six Sigma Green Belt (LSSGB). Advanced Project Management. Certified Campus Recruiter – recruited engineering graduates from New England Universities & Corporate Leadership Development Program candidates from MIT’s Sloan School of Management.
Co-author & Presenter: “Redefining the Economics of Multichip Modules” – International Society of Hybrid Manufacturers (ISHM), Denver CO.
Software/Systems Experience: Corporate PDM, ERP and Quality applications; Word, Excel, PowerPoint.
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