Lean Manufacturing Operations or Quality Manager/Leader LSSBB

Gerald M. Hoel

Phone (***) ***–**** • ******.*.****@*****.*** New Braunfels, TX 78132

SUMMARY OF QUALIFICATIONS

Lean Manufacturing Operations Manager/Leader over 26 years of experience derived through aerospace manufacturing, modifications, and repair station (FAR145). Possesses broad knowledge and practical application of Lean Manufacturing tools, able to manage company level operations using data driven decisions, with empowered employees. Using a Lean Six Sigma Quality System foundation to produce measurable, sustainable, financial results and achieve customer delight. Experienced organizational leader; managed a staff of 4 direct reports, 13 supervisors, 320 employees and previously 42 direct reports. Subject matter expert in teaching, coaching and driving change using all lean manufacturing tools. Proven ability to improve processes and operations; increased max capacity from 57 units per week to 220 per week, reduced overtime from 35% to 12%, improved the efficiency standard from 80% to 117%, Saving $2M on a fixed price contract, and $10M the following year, Man-hour reduction per aircraft 95K to 35K and 9.6K to 3.2K.

Areas of expertise:

Six Sigma

Lean Manufacturing

Kaizen Event Facilitator

Project Management

Value Stream Maps

OSHA VPP

Safety Management

Classified Security

Profit and Loss

Life Cycle Costs

Capital Investments

AS 9100 & NADCAP

Customer Liaison

Total Productive Maintenance High Performance Work teams

Single Minute Exchange of Dies

ISO 9001

ISO 14001

EDUCATION

Master of Science (MS) Aerospace Management (3.6 GPA) (2010)

Embry Riddle Aeronautical University World Wide, San Antonio, TX

Bachelor of Science (BS) Professional Aeronautics Management (3.9 GPA) (2007)

Embry Riddle Aeronautical University World Wide, San Antonio, TX

Lean Six Sigma Black Belt Certification – Villanova University, Villanova, PA (4.0 GPA) (2008)

Lean Manufacturing Certification – Villanova University, Villanova, PA (4.0 GPA) (2007)

Management, Supply Chain Management, and Safety Certifications (4.0 GPA) (2006)

Embry Riddle Aeronautical University World Wide, San Antonio, TX

PROFESSIONAL EXPERIENCE

Senior Quality Engineer / Continuous Improvement Leader Oct 2013 – Jan 2017

CFAN / GE Aviation, San Marcos, TX

Executed and improved the Quality Management System for CFAN ensuring compliance of AS9100

Prepared site level to meet requirements for NADCAP, assembled the team and inspection criteria for NADCAP certification; resulted in passed the first inspection and the re-certification the following year.

Facilitated Kaizen events reduced cycle times by 10%, and improved on time delivery by 5%.

Reduced first time yield from 2.1 in 2014, to 1.6 in 2015, to 1.1 in 2016.

Provided lean manufacturing training to new hire employees: 5S, one piece flow, kaizen events, JIT and point of use kitting, High Performance Work Teams, Waste Walks, Six Sigma, Andon, Kanban, Change over, Set-up Reduction, Visual controls, TPM, Value Stream Mapping, and Mistake Proofing.

Lean Business Leader/Manager Oct 2010 – Oct 2013

CFAN / GE Aviation, San Marcos, TX

Supervised 4 direct reports, 13 supervisors, 320 employees, on 3 shifts, in 3 departments.

Trained 620+ factory and 120+ office employees in lean manufacturing tools: 5S, one piece flow, kaizen events, Just in Time, point of use kitting, Waste Walks, Andon, Kanban, Changeover Set-up Reduction, Visual controls, Value Stream Mapping, Mistake Proofing and many more.

Facilitated Kaizen events and 5S implementation; resulted in Increased fan blade production max capacity from 57 units per week to 220 per week; reduced overtime from 35% to 12% improved the efficiency standard from 80% to 117%.

Executed Lean Manufacturing with cross-functional teams, determined solutions for complex problems in 3 departments and integrated the support functions of Engineering, Quality, Finance, HR, EHS, and Facilities Maintenance for minimal production impact.

Reviewed customer demands and increase production through capital investments by partnering with Finance and increase personnel working with Human Resources to meet that demand.

Reviewed current capital investments, tooling, and equipment to adjust for life cycle and costs for future business needs with profit and loss.

Operations Manager Feb 2008 – Oct 2010

The Boeing Company, San Antonio, TX

Supervised 42 direct reports, working post customer delivery installations and modifications to C-17 Aircraft for United States, Canadian, British, and Australian Air Forces, daily liaison with final customers and DCMA.

Increased Cost Performance 110% and Schedule Performance 100% on time delivery of 19 aircraft saving $10M on a firm fixed price contract with profit and loss in 2009.

Improved Cost Performance 104% and Schedule Performance 100% on-time delivery of 10 aircraft saving $2M on firm fixed price contract with offshore customers and an average exceeds expectations on customer score cards which increased customer demand in 2008.

Used Kaizen events and lean training, implemented: 5S, point of use tooling, kitting, and team boards.

Received a personal award reading, "far exceeds expectations in: finds a way, inspires others, delivers results, and charts the course."

Industrial Engineer / Lean Integration Mar 2001 – Feb 2008

The Boeing Company, San Antonio, TX

Trained internal and external customers of 1000+ employees for Lean Manufacturing tools starting with 5S, one piece flow, and kaizen events.

Trained smaller groups with, Just in Time and point of use kitting, Waste Walks, Andon, Kanban, Set-up Reduction, Visual controls, Value Stream Mapping, and Mistake Proofing.

Performed Kaizen events and value stream mapping site level of 2500+ employees and involved in site wide lean implementation.

Reduced the KC135 program man-hours from 95K to less than 35K hours.

Reduced 135 Modification Program reduced man-hours 9.6K to 3.2k hours; resulted in Shingo Award finalist 2007 and Atlas Awards 2003, 2007.

ADDITIONAL WORK EXPERIENCE

Avionics Technician The Boeing Company, San Antonio, TX

Operational test and check avionics systems in preparation for delivery, trouble shooting those systems and repair as needed.

Avionics Division Chief United States Marine Corps, Cherry Point, NC

Implemented of HPWT in the avionics division, teaching 5S, and lean manufacturing; resulted in 1998 "No findings" on a commanding general's biannual inspection and Awarded "Avionics Man of the Year" Marine Corps Bases East 1999.

Managed training, and mentoring 15 direct reports in the troubleshooting, repair, and maintenance of avionics systems for HH-46D and C-9B/DC-9 rotor-craft & aircraft

Quality Assurance Inspector, safety of flight on HH-46D and C-9B/DC-9 rotor-craft & aircraft for the avionics division.

Avionics Technician United States Marine Corps, New River Air, Jacksonville, NC

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