Manager Six Sigma
Resume:
Ronald Shaffer
Gurnee, IL ****1
******.*.*******@*****.***
Summary:
An experienced professional leader, able to sort through the clutter and respond with creative solutions.
Driven for action. Fascinated by ideas. Passionate for improvement.
Able to see patterns where others see complexity.
Signature Strengths: Learner, Ideation, Analytical, Strategic and Activator.
Management experience includes:
Manufacturing, Operations and Distribution Management.
Multi-plant responsibilities in manufacturing, engineering and EHS.
Multi-national Manufacturing and Distribution.
Forecasting for highly seasonal product lines to maximize on-time shipments rates.
Certified Six Sigma Black Belt practitioner in DMAIC, DMEDI, DFSS, Lean.
Project Management for Improvement, New Products, Finance and new programs.
Proposed, justified, defended and lead CapEx projects.
Materials and Supply Chain Director minimizing cost and controlling inventory value.
Engineering Manager improving and growing the product offering.
Quality Assurance Manager maintaining and exceeding product standards.
System Implementation and upgrades (MRP, ERP, AutoCAD, ProE, etc.).
Business Systems Development pushing systems to their limit.
Environmental, Health & Safety Director bringing company to compliance.
Corporate Trainer for Environmental, Safety, Improvement and New Products.
Facilities, Security and Real Estate.
Implementation Leadership Team for Municipal Paramedic program.
Professional Experience:
RGP, Inc. an International Consulting Firm February 2016 to Present
Consultant, Supply Chain, Production Support and Continuous Improvement
I am called to work side-by-side in partnership with business leaders and teams to drive organizational improvements, offering strategic and practical solutions. In collaboration with senior business leaders I help clients manage supply chain priorities including process improvement, strategic sourcing, supplier contract management and support production and manufacturing.
Independent Consultant, self employed February 2015 to January 2016
Continuous Improvement, Supply Chain and Manufacturing
Working with small companies to sell Continuous Improvement programs for their company.
L&M Kenosha County, WI March 2014 to January 2015
Director of Continuous Improvement / Plant Manager
Manufacturer of low to mid-volume corrugated boxes printed with up to 3 colors.
Instituted scheduled Preventative Maintenance program and decreased Maintenance head count 33%,
Installed ancillary equipment to increase productivity and decrease waste contributing to:
Increased output per man hour (DL & IL) 22% and set an all-time total production output record for the facility,
Sustained a 20% long-term growth initiative while reducing manufacturing headcount 10%,
Maintained over 99% on time delivery,
Set all-time company record for monthly production throughput by 5%.
Star Creations Lincolnshire, IL June 2013 to October 2013
Director of Manufacturing Operations
Manufacturer of high volume framed wall art for the retail market
Short term assignment where immediate priorities were:
Increase productivity by 20% overall:
Employed principals of Heijunka to increase throughput 40 to 50% on priority lines,
Met all KPIs for cost, quality and productivity.
Set all-time shipping record.
Improve on-time shipping to meet customer demand,
Increased on-time shipments from 90% to 99% through added capacity and increased productivity.
Organize the manufacturing floor to eliminate waste,
5S project increased available manufacturing floor space for 2 additional lines.
Improve and increase new product development,
Increased new product introductions by 35%.
IEA, Inc. Kenosha, WI, Menomonee Falls, WI, Barnesville, GA, Griffin, GA, Raymond, WI
Director May 1998 – November 2012
Manufacturer of design-to-order large engine cooling systems and radiators.
Attained Certification in Six Sigma as a Black Belt with DMAIC, DFSS, DMEDI and Lean training.
Director that demonstrated expertise in: Manufacturing Operations, Environmental, Health & Safety, Engineering, Supply Chain, Security and Six Sigma Black Belt Practitioner reporting to the majority owner; leading cross functional project teams.
Spearheaded effort to attain two major customers’ Quality System Certification.
Performed as Lead Six Sigma Black Belt to implement Six Sigma across the company; completed the largest number of projects and generated highest results.
Analyzed Engineering work flow resulting in reduced Dept. lead-time from a week to less than one day with machine code generated and quotes submitted.
Applied DMAIC methodology to Safety and cut the Mod Factor by 50%.
Conducted Lean Office projects to increase throughput, accuracy and efficiencies in Purchasing and Production Control.
Trained, mentored and certified 18 Green Belts with major project experience.
Responsible for all compliance issues including local, state, federal regulations and the terms of the Quality Management System, (based on ISO9000:2008), and customer certifications from Caterpillar and Cummins.
Lead a cross-functional team that delivered a functioning major change to a key manufacturing process which reduced the process rejection rate from 17% to <0.1%, reduced labor 90%, and reduced Hazardous Waste 95%.
Company Liaison for Quality, APQP, NPI and Engineering to outside interested parties; generated trust with Caterpillar resulting in face to face meetings becoming phone conferences.
Developed seismic compliance program meeting International Building Code requirements; Created design updates to meet Code, designed and managed the test and certification program. Attained certification first attempt.
Wrote and maintained Safety and Environmental Policies, procedures, and work instructions
Conducted training at all plants per OSHA, EPA, DOT, NFPA, OSHPD and FDA requirements.
D&K, Elk Grove Village, Illinois August 1996 to March 1998
Operations Manager / Quality Assurance Manager / Division Steering Committee
Manufacturer and converter of laminating film sold to the educational, printing and consumer markets.
Created and implemented a long-range inventory plan to meet seasonal demand.
Developed algorithm that included finite capacity planning to improve service levels and operate within physical constraints.
oAltered warehouse schema to implement algorithm generated changes
oAltered production strategy to implement algorithm generated changes
Introduced Standard Work Flow to increase throughput and Quality.
Echlin Inc., August 1988 – March 1996
Automotive aftermarket and OEM automotive component manufacturer and distributor.
Blackstone Mfg. Co. Chicago, IL (Division of Echlin Inc.) October 1994 – March 1996
Director of Materials Management
Managed Purchasing, Production Control, Supply Chain and Inventory functions.
Negotiated a major steel supply contract for 4 corporate divisions with a 20% cost reduction.
Championed project to accept a dead product line from a sister company, revamped product line, and instituted proper manufacturing methods to take the line from declining sales and a $1 million annual loss to increasing sales and a $1 million profit on $6 Million sales.
Diagnosed major system failure; worked with consultant to correct which allowed better availability of incoming product with less expediting.
Echlin Fuel Systems Group / Mr. Gasket High Perf. Group January 1993 – October 1994
Group Director of Materials Management
Materials Management and Operations trouble shooter, coordinator and advisor for a group of six plants manufacturing and distributing automotive fuel system components and high performance automotive parts and accessories.
Assisted group plants with Business Plan development for Operations and Strategic aspects; wrote initial turn-around Business Plan for new acquisition in the consumer marketplace (acquisition was bought out of bankruptcy).
Diagnosed inter-company supply relationships that caused customer service failures which resulted in increasing service levels from 75% to 98%.
Chaired Task Force to analyze benefits of moving the distribution of a $20 million product line resulting in a before tax benefit of $1 million; named Project Leader for the resulting move which was accomplished within a planned 2-day interruption of business.
Echlin Inc. Corporate Materials Dept. Branford, CT April 1991 – December 1992
Corporate Manager, Planning Systems Development
Created proprietary algorithm for forecasting automotive aftermarket parts demand with significantly better results than industry standard programs including MiniTab.
Developed new Planning System strategy; presented to Divisions and monitored progress.
Worked on corporate assignments and functioned as an “in-house” consultant for Materials and Operations opportunities.
Declared “Company Forecasting Guru” by the CEO and Chairman of the Board.
Assisted a machining plant manager to reduce costs, set strategy and keep plant open.
Lift Parts Mfg. Co., Inc. Des Plaines, IL (wholly owned division of Echlin Inc.)
August 1988 – April 1991
Operations Manager
Supervised Operations Department, which included Purchasing, Planning, Manufacturing and all Distribution/Operations functions.
Increased service levels from 85% to 99% in two years, increased inventory turns, held financial inventory flat and added 5,000 new products for foreign applications to a product line with 19,000 products.
Rewrote and updated purchasing policies resulting in a 75% reduction in excess inventory.
Revamped IT programs and policies to increase service levels.
Functioned as a Product Manager for 5 small product lines; doubled sales in 4 lines, decreased cost in remaining product line which increased sales 25% at identical margins.
Education, Training and Affiliations:
Bachelor's Degree from Eastern Illinois University,
Certified Six Sigma Black Belt (Process and Transactional; hard parts and financials),
Design For Six Sigma Training - ASQ,
OSHA 8 Hour Training - OSHA,
EPA Visible Emissions Evaluator certification,
Minitab Statistical Software training through Caterpillar University and Minitab,
SQL, VB.NET and Crystal Reports through College of Lake County,
MS Office through Echlin and Gateway Tech College (Word Excel PPT Access)
MS Project, MS Visio, MS Visual Studio, R statistics programming language,
ISO9000:2008 Internal Auditor, Lean Manufacturing, Value Stream Mapping, New Product Introduction, Failure Mode and Effects Analysis (FMEA), Caterpillar Production System (CPS) Green Belt through Caterpillar University,
Principles of Accounting and Financial Reports,
Principal member of the NFPA Standard 37 Technical Subcommittee,
Industry Advisory Council member of the UW-Milwaukee Mechanical Engineering Dept.
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