Dennis Pezan, MSE, MBA

ad05a2@r.postjobfree.com

815-***-****• Saint Charles, IL, 60175, US

Profile: C-Suite Executive

Manufacturing Operations Engineering Quality Lean Six Sigma Black Belt

Results-focused and strategically adept executive with a distinguished career in leading cross-functional teams, spearheading operational enhancements, fostering innovation, and driving revenue growth in diverse manufacturing sectors.

Exemplary in orchestrating cost reduction, productivity amplification, risk mitigation, and operational refinement through incisive root-cause analysis, judicious corrective actions, and the adept incorporation of cutting-edge technologies and lean manufacturing paradigms. A formidable catalyst in corporate strategy, delivering critical counsel to C-suite executives to fortify strategic blueprints, expedite judicious decision-making, and harmonize technological initiatives, capital expenditure plans, and overarching business vectors with long-term institutional goals. Equipped with a multifaceted background spanning Research & Development, Engineering, Product Supply Chain, Quality Assurance, and Financial Management. Adept in the stewardship of high-stakes, multimillion-dollar projects, excelling in cost supervision, profitability optimization, resource allocation, and fiscal prudence. An analytical luminary, renowned for orchestrating seamless collaboration across diverse functional teams to achieve outcomes that are both exemplary and in perfect alignment with organizational imperatives. Consistently recognized for the punctual and budget-conscious delivery of high-impact initiatives.

Manufacturing Industries Automotive, Aerospace, Electrical, Telecommunications, Medical, Biometric Technology, Security Systems, Architectural, Air Compressor, HVAC, Refrigeration.

Areas of Expertise

Strategic Planning & Operational Excellence

Leadership & Team Development

Revenue Optimization & Cost Efficiency

Inventory Control & Strategic Sourcing

Design Optimization for Manufacturability

Merger & Acquisition Strategy and Integration

Global Supply Chain & Logistics Management

Policy & Regulatory Governance (ISO, IATF, AS)

Continuous Improvement & Lean Principles

Quality Management & Risk Mitigation

Manufacturing Processes

Plastic Extrusion, Injection Molding, Coiling, Cold Forming, Metal Fabrication, Punch Press, Metal Finishing, Tube Bending, Laser Cutting, Plating, Powder Coating, Heat Treating, Welding, 3-axis CNC Machining, 5-axis CNC Machining, Tool & Die Machining, Secondary Operations, Coordinate Measuring Machine, Powder Coat, Metal Stamping, Polishing, Acid Etch Glue, Paper Saturation, Hot Bonding Automation, Electrical Assembly, Electro-Mechanical Assemblies, Biometrics Assembly, Industrial Compressor Assembly, Refrigeration Assembly, Packaging Design, Packaging Automation, Warehouse Distribution.

Leadership Style Emotionally Intelligent and Strategically Transformational, proficient in galvanizing multidisciplinary teams across diverse manufacturing sectors. Exceptional at steering enterprise-level projects and aligning them with long-term organizational goals, thereby achieving optimal financial and operational outcomes.

Selected Accomplishments

Introduced efficient technical processes and drove automation at Lake Zurich plant. Created significant business impacts, including over $1.5M cost savings and reductions in time consumption for several processes including slashing inspection response time from 2.5 days to 0.5 days.

Minimized labor headcount by 50% at Okeechobee plant in 4 months ($1.25M), optimized lead time at Rantoul plant to 4 weeks from 8, eliminated highest problematic customer rejects area to ZERO at fiber pedestal line at Canton plant, and reduced US Cellular unit cost by 25% at Schaumburg.

Generated multimillion-dollar cost savings; reduced total scrap to 1.29% ($750K), inventory inaccuracies by 50%, and overtime by 80%; maximized production capability for General Motors line and Kenworth assembly line; and yielded 99% improvement in PPM for customer Paccar.

Grew $8.5M revenue by growing Security business across Latin America; completed M&A integration and plant consolidation for 3 plants resulting in saving over $20M per facility; and introduced multimillion-dollar cost reductions, significant time savings, and impactful process improvements.

Grew revenue by 100% through an APQP/RFQ process; Ensured initial certifications and regular compliances with ISO 45001, ISO 14001, and ISO 9001; eliminated all external audit non-conformances to zero YOY; and generated productivity improvement of $50M by moving high volume lower grade product offering to Mexico plants.

Implemented OPEX and Continuous Improvement projects in the Southwest region facilities; generated $15M in cost reductions through consolidation of 5 business units; and enabled $6M cost savings through various initiatives.

Implemented Demand Flow Technology, 1-Piece Flow, Kanban System, and Pull System methodologies throughout the assembly areas increasing throughout by 100%.

Career Experience

Vice President of Operations, Flexible Liquidtight Conduit, Electri-Flex, Roselle, IL Jun 2022 – Present

Oversight of manufacturing operations with a focus on strategic planning, P&L management, and day-to-day operational excellence. Instrumental in formulating and implementing innovative strategies to enhance productivity, reduce costs, and drive organizational growth.

Strategic Initiatives:

Facility Overhaul: Revived and led a previously stalled $10M plant redesign project to successful completion.

Departmental Restructuring: Devised the reorganization of the engineering department, significantly improving response times.

Talent Acquisition: Skillfully recruited key personnel from competitor following their plant closure.

Quality and Compliance:

Quality Systems: Spearheaded the organization-wide implementation of PPAP processes, fortifying quality control systems.

Training Programs: Launched specialized extruder training, offering bilingual content to ensure workforce proficiency.

Innovations and Process Improvements:

Cost Optimization: Engineered a 90% reduction in city water usage, translating to monthly cost savings of $15,000.

Employee Engagement: Formulated a comprehensive recruiting and retention program, successfully elevating Google, and Glassdoor ratings.

Safety Training: Instituted OSHA-compliant video training for all employees to standardize and audit safety protocols.

Technology and Tools:

Engineering Workflow: Conceived and deployed a KPI-driven workflow system, initially rolled out to Customer Service and Sales departments.

Maintenance Management: Initiated and implemented a digital work order system, currently in trial phase at the West plant.

Documentation and Training:

QMS Control: Established 46 bilingual operator-level procedures, work instructions, and reference sheets via SharePoint, targeting full integration into training programs by year-end.

Director of Engineering & Continuous Improvement, Network Infrastructure, Amphenol, Wallingford, CT Mar 2018 – Jun 2022

Introduced process improvements and upgrades through P&L initiatives and projects across 7 company manufacturing sites. Instituted goal-oriented, quality-driven, and customer-focused engineering operations throughout strategic supporting departments such as engineering design, R&D, marketing, technical services, product management, and global supply chain. Focused on enhancing efficiency, driving automation, and ensuring zero defects to customer while conceptualizing and executing strategies and pipeline projects. Processes included Metal Fabrication, Powder Coat, Assembly, Packaging Design, Composite Manufacturing, Injection Molding, Plastic Extrusion, wire forming, rolling mill, heat treat, CNC machining, and machine design.

Provided strategic direction and leadership to drive, modify, and support engineering processes of design and manufacturing of high-end complex components and assemblies along with enforcing quality standards.

Generated $1.5M cost savings by introducing and implementing automatic inspection measuring equipment resulting in slashing inspection response time from 2.5 to 0.5 days.

Saved $250K of RGA costs by pioneering 24-hour fast technical response system to support overseas customers, replacing 5-days legacy system.

Led several process changes and innovations including new paperless technology, Bluetooth wireless gages, auto data collection for load testing measuring equipment, bar coding scanning, calibration printed labels, and custom databases.

Drove productivity, optimized resources, and reduced direct labor headcount by 50% in four months at Okeechobee plant.

Accelerated manufacturing processes at Rantoul plant and slashed lead time from 8 to 4 weeks for CPAD product line.

Minimized human / machine errors at fiber pedestal line in Canton, MO, and eliminated all customer rejects from 12 issues per quarter. Customers included Verizon and US Cellular.

Incremented performance stats by implementing electronic monitor board to display jobs progress, increase CMM lab throughput, and create SPC charts.

Introduced cost-effective Design for Manufacturing improvements which reduced US Cellular unit cost by 25%.

Partnered with DuPage WorkNet to provide jobs for RAMP-UP individuals benefiting on labor expense reduction by 50%.

Planned and achieved $1.5M annualized savings through strategic policy deployment improvements around Hoshin-Kanri X Matrix.

Regional Quality Manager, Combustion Technologies Sector, BorgWarner, Auburn Hills, MI Feb 2014 – Mar 2018

Directed, at multiple sites, quality assurance and compliance with company standards and industry best practices to standardize and validate various processes, including metal fabrication and finishing types, acid etch glue, paper saturation, hot bonding automation, clutch assembly, and packaging automation. Aimed at driving manufacturing efficiency and enabling customer satisfaction while leading continuous improvement initiatives within the transmission technologies sector.

Led significant cost savings through reductions in total scrap from 2.30% to 1.29% 75M); inventory inaccuracies and shortages (shrink) by 50% (~$2M); and overtime by 80% through implementation of 4-shift operator model.

Increased potential revenues by enhancing process capability from Cpk 1.0 to 1.67 in General Motors line.

Developed and executed implementation plan and schedule for IATF 16949: 2016.

Drove production efficiency in Kenworth assembly line and improved OEE from .33 to .83 by implementing OEE system.

Pioneered red-tag process and optimized production floor space by 50% to expand space for potential future business.

Enabled 99% improvement in PPM (872 to 13) through quality improvement plan.

Originated and authored Metal Fabrication Supplier Quality Manual for direct materials procurement.

Lean Six Sigma Black Belt, Global Logistics & Supply Chain, Ingersoll Rand, Carmel, IN Jan 2010 – Feb 2014

Planned and implemented strategic Lean Six Sigma projects within company’s operating system across North and South America. Created significant impacts in the areas of marketing, customer service, inventory, global logistics, manufacturing costs, and process capability.

Originated new scrap process and led $2.5M improvement at a $225M COGS operation through COPQ ratio reduction from 4.10 to 2.51.

Boosted YoY revenue growth by 40% from $6M to $8.5M by growing ST business across Latin America.

Generated inventory reduction impact of $2.6M and doubled inventory turns by driving manufacturing plants and supply chain inventory improvements.

Tailored process and structure for Product Catalogs and Pricing Books resulting in 50% reduction in lead time and $2.2M increase in revenue.

Championed M&A integration and plant consolidation of three manufacturing businesses in Brea CA, Golden CO, and Parsippany NJ, creating cost reduction impact of $20M per facility.

Regional Operations Excellence Manager, North America Operations, Ingersoll Rand, Colorado Springs, CO Jan 1995 – Jan 2010

Managed strategic product launches, supplier development, supplier risk mitigation plans, and outside processing initiatives for the Schlage Electronic Access Control products. Responsible for the plant’s compliance requirements including OHSAS 18001, EHS 14001, ISO 9001, and Sarbanes Oxley. Concurrently a strategic member of the Corporate Lean Team that facilitated multiple kaizen improvements in North America.

Managed Profit and Loss margins for Latino Supermarkets customer orders in the southwestern region including manufacturing the orders, distribution, installation, and service.

Manager of 100+ union workers (Carpenters and Joiners, Teamsters, Sheet Metal Workers, Pipe Fitters) for merchandising units and refrigeration system units.

Led VAVE initiatives for the identification, analysis, and implementation of the OPEX maturity program and $1.5M in material and labor-saving improvements totaling $6M.

Project managed the relocation and consolidation of 5 Ingersoll Rand Business Units including 2 manufacturing plants, service, sales branches, and construction group worth $15M in cost reductions.

Developed an APQP/RFQ process to grow and execute effectively “specials” type orders. Accomplished goal by bridging gaps between current product offering and customer’s needs that were not being met. The program grew in revenue by 100%.

Developed “Great Product-Process-People” methodology to drive process certification, continuous bi-annual quality training and strict product testing policy.

Directed the initial certifications and bi-annual audits of ISO 9001, EHS 14001, and OHSAS 18001. Reduced the number of external audit non-conformances to zero YoY.

Led all the initiatives for transitioning product lines from Security Colorado to Ensenada Mexico generating a productivity improvement of $10M.

Led the deployment of a new supplier quality program and reduced supplier DPM by 66% and reduced MRB material dollars by 77% at inception.

Implemented demand flow technology: 1-piece flow, Kanban, Pulling system throughout the business units.

Managed testing laboratory. Supervised various destructive and non-destructive tests, provided reports and analysis, and supplier material rejections validations.

Led all the research and development product integrity activities for future product launches and supported quality by testing current portfolio and comparing them to BHMA compliance requirements.

Developed CNC programs for vertical and horizontal mills and lathe machines, procured equipment and tooling.

Additional Experience

Ingersoll Rand: OPEX Lean Leader / Supplier Quality / Manufacturing Engineer – Southern California

Languages Fluent in English and Spanish (Speak, Read, Write).

Formal Education

Master of Science, Engineering Systems, University Southern California, Los Angeles, CA

Master of Business Administration, Operations, Colorado Technical University, Colorado Springs, CO

Bachelor of Science, Manufacturing Engineering, California Polytechnic University, Pomona, CA

Associate of Science, Machining Technology, Rancho Santiago College, Santa Ana, CA

Industry Certifications

Lean Six Sigma Black Belt

Creating World-Class High-Performance Manufacturing thru OPEX at Ingersoll Rand

TL9000, AS9100, ISO9001, ISO13485, ISO14001, ISO45001, IATF16949 Quality System Lead Auditor

Honors & Awards

Illinois Workforce Innovative Solutions 2019

DuPage College MSSC Instructor 2018

CEO Executive Award 2015

Longevity Award 2012

Lean Six Sigma America’s Team 2010

President’s Award 2009

President’s Award Nomination 2008

Outstanding Performance Award 2005

Top High Potential Talent Award 2004

Top Lean Leader Award 2003

Community and Industry leadership

Class Instructor Technology and Manufacturing Association (TMA), Schaumburg, IL Jan 2023 to Current

Taught various in-class courses (English and Spanish) to individual students and member companies in shop mathematics, quality instrumentation, blueprint reading, Computer Aided Design, Geometric Dimensioning and Tolerancing, and Computer Numerical Control.

Adjunct Faculty, College of DuPage (COD), Glen Ellyn, IL Aug 2018 to Current

Intensive teaching of the Manufacturing Skill Standards curriculum in Environmental Health and Safety, Quality Systems and Control, Manufacturing Processes, Production Control and Machine Maintenance and Hands-On training through Amatrol’s Skill Boss equipment.

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