Matthew W. Bellonis

Gallatin, Tn., *****

Cell: 615-***-****

act9ar@r.postjobfree.com mailto:act9ar@r.postjobfree.com

Operational Excellence Manger

Lean transformation leader with a broad cross-functional background and experience in mid-volume vertically-integrated operations including: Aerospace manufacturing, Aircraft maintenance, repair & overhaul (MRO), Medical device manufacturing, Electronics manufacturing, Metal fabrication /manufacturing, Marine port/ terminal operations and warehousing and distribution operations, as well as demonstrated successes across transactional businesses and IT environments.

Responsible for driving overarching strategic direction, coaching and global leadership on the implementation of the LSS Lean Enterprise programs and continuous improvement (CI) efforts throughout the company’s commercial divisions and operational functions.

Results-oriented leadership style with strong influencing skills and abilities to make an immediate and enduring organizational impact.

Trained and mentored over 350 Green Belts, 150 Black Belts, 20 Master Black Belts while executing lean strategies and achieving measurable business results.

Operational Excellence Manager Ports America 03/13 – Present

Responsible for developing Ports America’s Lean CI transformation strategies /roadmaps and key performance indicators (KPIs), and overseeing, managing and executing Lean initiatives across all divisions consisting of 70 marine port terminals and shared service operations and functional areas.

Collaborate with global supply chain, engineering, operations and commercial leadership to provide strategic direction and translate strategies into actionable /measurable goals.

Work with site management to improve operating efficiencies, reduced asset/inventory cost, optimized labor ordering, ship discharge /re-load efficiencies (improved moves per hour (mph)), reduced crane change over times, reduced cargo damages and established standardized work /increased process capabilities.

Worked with IT and site users to review and test improved IT solutions to assure accuracy in cargo discharge, billing and customer invoicing.

Developed safety road maps, audit criteria and protocols to support reduction in LTIFRs and severe incident occurrences.

Achieved the following annualized financial results: FY-2013 $6.mil annualized EBITDA savings, FY-2014 $8 mil annualized EBITDA savings, and FY-2015 $8 mil annualized EBITDA savings.

Sr. Process Excellence Manager Ft Rukers, AL 03/12 – 03/13

Developed and supported TOC, Lean Six Sigma program designs for 12 airfields operations and maintenance, repair and overhaul (MRO) facilities to support rigorous helicopter flight schedules. Developed critical chain project management - TOC /Lean designs focused on improving aircraft repair and overhaul efficiencies helped achieve 32% reduction in CH-47 turnaround time, 52% reduction in UH-60 turnaround time.

Supported management and maintenance personnel in critical chain /constraint management and Lean designs

Mentor and led Greenbelt and Black belt projects achieving annualized savings through reduced A/C inventory and labor hour reduction $3 mil.

Support transition from AS9100 to AS9100C: Quality Management Systems - Requirements for Aviation, Space and Defense Organizations transition

Interface with /Army supply chain, engineering, operations and customers to coordinate and resolve routine quality-related problems and improve processes

Support ISO14001 and OHSAS 18001 implementation and auditing.

Perform value stream mapping /analysis on core maintenance and overhaul processes.

Lean Six Sigma Master Black Belt Afghanistan 06/11 – 03/12

Worked with senior military and civilian leadership to provide in theater operational /logistics analytics and modeling support for forward operating base closures, equipment movement, establishing staging yard capacity and export capabilities.

Developed unique models to analyze equipment movement from in theater Forward Operating Base (FOBs) to approved staging yards.

Analyzed MRO rework capabilities, defined yard capacity storage and flow limits, rate of travel, FOB equipment requirements etc.

Provided Black Belt project support with emphasis on improved MRO capabilities and increased throughput.

Train, mentor, and develop Green Belt and Black Belt candidates.

Senior Business Analyst Dynamics Research Corp 07/06 – 06/11

Work with Navy /Marine Corp military and civilian leadership to implement and deploy a globally-connected TOC/Lean CI strategy. Facilitated the creation of an Enterprise-wide CI culture and use CI methodologies to drive core/strategic processes to respond to the needs of customer.

Oversaw, managed and facilitated a standardized LSS Lean initiative and CI strategy across multiple divisions and functions achieving the following annualized enterprise cost savings: FY-2008, $29 mil, FY-2009 $32 mil FY-2010 $28 mil and FY-2011 $28 mil,

Coach leadership (at all levels) through the lean and six sigma implementation strategy for the business focused on delivering business results and building competency in lean methods. Provide leadership/mentoring/training to all levels of the organization on the use and practice of Lean methodology and tools (e.g. 5S, visual controls, standardized work, VSM & A3, Heijunka, Jidoka, Kaizen, SMED, etc…); facilitate large-scale, cross-functional kaizen events

Work with Missle Defense Agency /PAC-3 Misslle’s supply chain, engineering and operations leadership to provide strategic direction and translate strategies into actionable /measurable goals to improve systems capabilities and on-time delivery of project scope

Lockheed Martin, Missile Fire Control Division’s - Preferred Supplier Program in support of the MDA PAC-3 Missile. – Performed analysis of core VSMs and capability analysis to improve systems quality /improved on-time delivery.

Mgr QA / Process Excellence DRS Laurel Technologies 07/04 – 07/06

Develop infrastructure tools and materials, including training to support the Company’s lean initiatives. Conduct workshops and other training programs that foster cross functional deployment of Lean Methodology.

Worked with all elements of the business to integrate Lean Six Sigma CI to include engineering, new product development, supply chain, inventory management, and production control

Provided business case for prioritizing high-impact opportunities establishing links to business strategies and sustainable process improvement

Responsible for managing standardized QMS results for the following QA functions: QA Mgr., QEng. SQEng., QAudit, QTech, QMech Insp, in-process & final test at manufacturing facilities in the US and Canada.

Serve as management representative for external registrars (QA & Safety), DoD, FAA and ISO9000, AS9100, ISO14001, OHSAS 18001,CMMI, QMS/EMS/OHSAS audits.

Responsible for organizational supplier quality qualifcations, NADCAP process audits and accreditation and FRACAS/CAR /SCAR programs,

Provide QE support for the following value streams: Discrete industrial cable manufacturing, Circuit card assembly, Electronic box build, Software design, box test and final test. Responsible for the following QA functions: design, engineering, rapid prototyping, in-process test, inspection, electronic testing, software protocols and testing.

Preparation of validation protocols, compliant reviews, validation reports, FAA interface.

Prepar and approved specifications and testing requirements for all new materials, intermediates, and final products.

Perform out-of-spec investigations and evaluate their impact on product quality.

Managed corporate level supplier quality programs, - CTQ /design specifications are communicated, verified and validated prior to delivery.

Manage Corrective and Preventative Action programs including CAPA, 8-D Boeing CAR /Root Cause Analysis and Voice of Customer (VOC) initiatives.

Division QA Mgr. Goodrich Aerospace Corp. 08/01- 07/04

Division QA manager responsible for QE and manufacturing quality functions at three plants including metal fabrication, elastomeric (rubber) de-icing systems. With responsibility for FAA Parts Manufacturer Approval (PMA) CFR 14 part 21 and 145 Repair Station and integration of the AS9100 quality management systems (QMS) requirements.

Manage NADCAP audit and accreditations supporting the following approved DSSD processes: Chemical Processing (CP), Coatings (CT), Composites (COMP), Conventional Machining as a Special Process (CMSP), Elastomer Seals (SEAL), Electronics (ETG), Heat Treating (HT), Measurement & Inspection (M&I), Metallic Materials Manufacturing (MMM), Sealants (SLT) and Welding (WLD) Provided QE support for NADCAP process audits and accreditation.

Manage Design for Six Sigma (DFSS) /Design for Manufacturing (DFM), Advanced Quality Planning and New Product Introduction (toll-gate) reviews and risk mitigation processes including Airbus (GRESS), Rolls Royce (SABRE) Boeing (D9100) programs

Manage Supplier Quality Engineering: Supplier SCARs, FRACAS 8D, Supplier Audits, FMEA, Control Plans

Responsible for receiving, in process test, final inspection and final assemblies.

Coordinate and led the following activities: FMEA (Design & Process), MSA, Control Plans, Inspection and testing specifications.

Perform out-of-spec investigations and provided risk /impact on product quality evaluation.

Provide analytical support for new products, process improvements.

Support process engineering /in-process optimization

Manage Corrective and Preventative Action programs including CAPA, FRACAS, Root Cause Analysis and Voice of Customer (VOC) initiatives.

Employment History:

2013 to Present Ports America Director, Process Excellence, Safety

Marine/Terminal Operations LSS Master Black Belt

2011 to 2013 Army Fleet Services Sr. Manager – Cont. Improvement

Ft Rucker, Al (multi-airfields / MRO aerospace maintenance)

Calibre Systems Predictive Analytics

Afghanistan LSS Master Black Belt

HQ - Kabul, Afghanistan

2006 to 2011 Dynamics Research Corporation Sr. Business Analyst

Washington D.C. Lean /Six Sigma – TOC, Master Black Belt

(Navy/Marine contract) Navy /Marine Healthcare – CPI Programs

2004 – 2006 DRS Laurel Technologies Director, QA and Operational Excellence

Johnstown, PA (multi-plants /US & Canada) – DoD manufacturing

Electronics Mfg. Lean /Six Sigma Master Black Belt

ISO9001, ISO13485, AS9100, DoD

2002 – 2004 Goodrich Corp. Division Quality Assurance Manager (multi-site)

Union, WV Aerospace Manufacturing /FAA Rework Facility

ISO9001, ISO13485, AS9100,

2001 – 2002 Lockheed Martin Senior Quality Specialist (AS9100)

(FAA contract) Federal Aviation Administration

Washington, DC

1998 - 2001 Hamilton Beach Quality Assurance Manager (multi-site)

Memphis, TN QMS /ISO9001 - Lead Auditor

Supply Chain Management /Logistics /Distribution

1995 - 1998 Farr Company Inc. Quality Assurance Manager

(Pharmaceutical Filter Mfg.) ISO9001/QS901 (automotive) QMS - Lead Auditor

Holly Springs, MS

1993 - 1995 DuPont Corp., ICI Acrylics, Supplier Quality Engineer

Memphis, TN Specialty Chemical Processing

Education:

Excelsior College, BS Degree, Management, Business

Quincy College, AS Degree, Business Management

Penn Highland College, Adjunct Instructor – Lean Six Sigma Green Belt and Black Belt Courses

Professional Certifications:

ASQ - LSS Black Belt - #191 - February 2009 to June 2018

Supply Chain Design Technical Expert – Avraham Goldratt Institute - January 2007 to Present

Lean/Six Sigma Master Black Belt – DRS Laurel Technologies - March 2005 to Present

Critical Chain Project Management – CCPM - Realization - June 2012 to Present

Adjunct Instructor - Lean/Six Sigma Green Belt - Black Belt Instructor - Penn Highland Com College

Six Sigma Black Belt – Goodrich Aerospace Corp - May 2004 to Present

Lean Practioner /Lean Expert - Goodrich Aerospace Corp – May 2004 to Present

DoD Active Security Clearance: Secret

Professional Courses:

Lean Practioner /Expert – Goodrich Aerospace Corp.

Lean Six Sigma - Black Belt Instructor - Dynamics Research Corp.

Lean Six Sigma Black Belt – NOVACES

LM21 Lean /Sigma - Black Belt - Lockheed Martin

Lean Six Sigma Master Black Belt – NAVSEA University

Supply Chain Management Expert Training – Goldratt Institute

Supply Chain Management Deployment Training – Goldratt Institute

(ACE) Achieving Competitive Excellence – United Technologies

AS9100 / ISO 9001 / TS16949 Lead Auditor, Applied Quality Systems Inc.

Minitab Trainer: Intro to Minitab, Basic Statistics,

ISO9000 Internal Auditor Training Program, Goodrich Aerospace

OSHA Safety & Health Program, Department of Navy

SAPI – Systems Approach to Process Improvement – Department of Navy

Statistical Process Control for Industry and Service, Ford Motor Company

Team Oriented Problem Solving, 8-Disciplines, Ford Motor Company

(FMEA) Potential Failure Mode and Effect Analysis, (AIAG),

(PPAP) Production Part Approval Process, (AIAG),

(APQP) Advanced Product Quality Planning, (AIAG)

Introduction to Lean Manufacturing, (MEP)

Lean Enterprise Development, Department of Navy

SEI-CMMI, Based Appraisal for Internal Process Improvement. Carnegie Mellon, Software Eng., Institute

Navy Technical Schools

Instructor Basic Training

Facilitation Training

Instructor Airspeed – LSS Black Belt

Quality Assurance Administration /Logs & Records

Supply Chain /Logistical Management

Naval Safety Supervisor

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