TED SMITH, PMP

**** **** ******** ***** *********, CO 80128 303-***-**** acxde4@r.postjobfree.com

PLANT / MANUFACTURING MANAGER

Project Management / CPI / Supply Chain / Compliance / Six Sigma / QA & QC / Budgets New Product Launch / Cost Controls / Global Sourcing / Supplier Relations / Negotiations Utilizing my engineering and technical knowledge, I streamline operations, effectively manage the global supply chain, and introduce manufacturing efficiencies to ensure profitability. I am exceptionally adept at aligning production and distribution objectives while improving processes through ISO and Six Sigma Lean methodologies. My team building skills enable my divisions to continually exceed all internal/external guidelines and deliver top performance and superior results. I continually monitor quality control and assurance practices to increase operational efficiencies, delivery, and profitability in highly competitive environments. I have learned considerable mechanical engineering skills while applying an understanding of physics and mathematics to correct the root causes of technical problems as a manager and a manufacturing engineer. My key strengths include:

Launching new processes to strengthen production capabilities

Utilizing Six Sigma methodologies to enhance processes and improve quality

Solving tough manufacturing problems by focusing on customer needs and profit goals

Containing costs while increasing customer satisfaction

Establishing strategic partnerships to improve profitability and gain a competitive edge Described by others as an action and results-oriented leader, I synthesize critical information and make timely decisions in the best interest of both the company and customer. My credentials include a BS in Electronics Engineering Technology from CSU, PMP certification, and I am a Six Sigma Black Belt. SELECTED ACCOMPLISHMENTS

Improved project yield while reducing costs. Faced at Sypris with upgrading aging equipment to fulfill increasing demand. Determined outsourcing was less expensive than replacing old equipment. Negotiated contract with new vendor, reducing costs of subassembly 20%. Saved $1M budgeted for new capital equipment expenditures. Expanded market. Tasked to develop a supply chain for a Clinical Trial in India for a Strategic Partner. Researched the India Customs rules and researched the India regulatory constraints surrounding Corventis’ product. Developed business partnership with a value add partner to procure SIM card, install and provision SIM cards, and test the Product in India. Developed the processes and trained the value add partner. Developed the supply chain to get product from USA to India. Expanded product line. Tasked to find new instrumentation tape vendor after sole supplier went bankrupt. Developed specifications, test equipment/methodologies, ensuring quality product with new vendor. Discovered that the new tape failed error rate test because the surface of the new tape was not sufficiently smooth. Created an interim process to smooth the surface of the magnetic tape in my facility; while the supplier implemented a new formulation. Delivered tape to global clients on time and passed acceptance test, resulting in $2M additional annual revenue. Thrust into a new product which was stalled. Observed that the mechanical alignment of the tape transport was iterative, the goodness determined by subsequent testing, not deterministic based upon a tool at alignment. I replaced the goodness testing with a deterministic alignment process founded upon a fixture. The goodness testing required at least 40 hours per system (one pass, the typical system required 3 passes). The mechanical alignment required 20 minutes per transport and was performed once. The cost savings was $1000 per system, 40 systems per month. Improved Yields. Developed Yield metrics on Final Test of Product at Corventis. Inculcated metrics into organization, where no metrics existed. Drove yield from less than 70% to >99%. Mentored manufacturing engineers in root cause, pareto analysis, cause and effect, FMEA, and PDCA. Drove the improvements from Final Test to PCBA solder paste. Ensured product delivery deadline was met. New Sypris account required recorders earlier than scheduled. Managed all production aspects including PCB material shortages, supplier relations/negotiations, process requirements, purchasing, scheduling and logistics. Delivered 40 days ahead of schedule, reducing lead time 25%. Improved producibility, increased quality, reduced cost. Given responsibility for a different product, observed that the mechanical setup was iterative and slow. Developed process to quantitatively measure the track straightness of the helical scan recording. Thereby, establishing that the actual track was curved. Generated new mechanical setup process which yielded desired track straightness after one time. Reduced labor by 50%. Participated in Business Transformation at Sypris Electronics. The team used a Baseline process to quantify waste in the entire business. Based upon data, action plans were developed for each root cause of an UDE. The action plans were prioritized based upon likelihood of achieving an early win. The team conducted 16 Kaizen Events in 8 months resulting in reducing the factory footprint by 60%, improving cycle times by 70%, increasing on time delivery to 92%, and reducing scrap/rework by 70%.

Redesigned PCB, gaining competitive edge. Sypris’ outsourced PCB’s from Scotland were expensive and behind the times. Redesigned the circuitry using current technology and fiberglass substrate, reducing cost of part 50% and saving

$1M+ annually.

Managed NPI test project. Developed the test method a RAID based data storage product, including Production ATP, Design Verification Test. I wrote the test plans and managed the test engineers writing the test programs. The testing including temperature and vibration.

CAREER

Medtronic. The medical devices manufactured by my organization are on the cutting edge of providing Physicians with real time data to allow for preventative medicine.

Sr. Manager, Operations and Manufacturing, July 2011 to present. Direct all aspects of plant operations with a focus on ISO 13485 guidelines and FDA regulations. Manage organization thru metrics to maximize profitability, on-time delivery, quality and customer satisfaction. Responsibilities include purchasing, manufacturing engineering, shipping, receiving, IT, material/labor costs and safety. Develop Annual Operating Plan spreading the sales forecast into revenue based upon capacity and lead time. Generate budgets for labor, direct and indirect; inventory; expense items; facility; and capital. Manage staff of 20. Strong focus on NPI in a fast pace, global, regulated environment.

Sypris Electronics. Promoted to levels of increasing responsibilities for this global provider of electronics manufacturing and engineering services. The products manufactured by my organization are data acquisition and data storage systems sold to government agencies worldwide and scientific test community.

Plant Manager, January 2000 to July 2010. Directed all aspects of plant operations with a focus on CPI and ISO 9000 guidelines to maximize profitability, on-time delivery and customer satisfaction. Responsibilities included shipping, receiving, IT, engineering, material/labor costs and safety. Developed Annual Operating Plan spreading the sales forecast into revenue based upon capacity and lead time. Generated budgets for labor, direct and indirect; inventory; expense items; facility; and capital. Managed 45 staff and $10M budget.

Manufacturing Manager, July 1999 to January 2000. Oversaw all manufacturing operations including team of 40, $7M budget, shipping, receiving, engineering, and supply chain to ensure productivity, QA and delivery. Managed a PCB manufacturing department which produced thru-hole and SMT boards. Managed the project which selected, justified, and installed the capital equipment for a new SMT line.

Test Manager, November 1998 to July 1999. Oversaw test production division with on-time delivery, customer acceptance rate, labor costs and overhead as key performance metrics. Managed 15 and $1M budget. .

Manufacturing Engineer, March1994 to November 1998. Responsible for overcoming any technical challenges in manufacturing from procurement, assembly, test, and shipment. Evaluated on cost reduction projects, cycle time reduction, new product introductions. The areas of focus were manufacturing of Circuit Card Assemblies, manufacturing of cable harnesses, final assembly and final test. Honeywell Test Instruments (acquired by Sypris in 1998).

Manufacturing Engineer, March1985 to March 1994. Responsible for overcoming any technical challenges in manufacturing from procurement, assembly, test, and shipment. Evaluated on cost reduction projects, cycle time reduction, new product introductions. The areas of focus were manufacturing of Circuit Card Assemblies, manufacturing of cable harnesses, final assembly and final test.

Design Engineer, August 1984 to March 1985. Responsible for the electronic design of a circuit card assembly. Lockheed Martin.

Project Engineer, June 1980 to August 1984. Responsible for the technical aspects of all data storage systems on the P3C Orion aircraft. Traveled worldwide working with US Navy personnel, training and documenting processes. Additionally, responsible for troubleshooting problems and implementing corrective action. EDUCATION SUMMARY

Project Management Professional.

Received my PMP certification from Project Management Institute in 2009. Six Sigma Black Belt.

Received my Six Sigma Black Belt certification from Sypris Electronics in 2004.

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