Stanley MJ Baker

*** ****** **. ● Madison, AL ***58

● C: 256-***-****

ad07mk@r.postjobfree.com

www.linkedin.com/in/Stanley-Baker-OpEx-Lean-Sensei

Operation Excellence Leader with experience utilizing Total Quality Management, Lean Six Sigma and the Toyota Production System to drive organizational culture change. Able to guide and lead highly skilled, cross-functional teams in the design, development and launch of continuous strategic process improvements for both short-term and long-term goals in Safety, Quality, Delivery and Cost.

● Value Stream Mapping ● Overall Equipment Effectiveness

● Standard Work ● 6S Methodology

● Problem Solving & Root Cause ● FMEA

● Visual Management ● Continuous Improvement

● DMAIC ● Waste Stream (Green)

● KPI’s: FPY, OTD & IT ● Mistake-Proofing

● Quick Changeover (SMED) ● Total Productive Maintenance

● Gemba Walks ● Ergonomics

● Floor Plan – Spaghetti Flow ● KanBan

● Kaizen Events ● Model Cell

Core Compencies

● Program Management (PMBOK) ● Quality Assurance Control & Standards

● Project Management / Engineering ● ISO9001/AS9100

● Budget Planning & Administration ● ISO14001/ISO5001

● Production Control & Scheduling ● EHS OHSAS18001/ISO45001

● ERP/MRP Project Management ● Supply Chain Management

Sales Growth: Play key role in increasing sales via acquisitions, mergers, effective sales & marketing and operations management strategies.

Product Development: Led teams in the Introduction of New Products to meet design criteria for Manufacturability, Testability and Excellence. Including ROHS & WEEE.

Process Improvements: Drive change with Standardized Work, Just-In-Time Systems and elimination non-value-added activities (waste). Utilize Six Sigma Techniques to establish baseline, reduce variation and eliminate defects.

Operational Improvements: Drive change with Integrated Management System that defines where the company is going, identify risks, mitigate them, manage change and continuously improve. Use Operational Discipline to do the right thing, the right way, every time.

Logical Solutions, LLC – Madison, AL (2003 – Present)

● Owner/Founder/Lean Sensei: We are an Engineering Consulting Firm specializing in Lean Manufacturing with the sole purpose of defining, designing and implementing continuous strategic improvements in support of our Customers Operational Excellence goals and objectives in Safety, Quality, Delivery and Cost. We teach, mentor and coach individuals throughout the organization to see the process, improve material flow and eliminate waste using Total Quality Management, Lean Six Sigma and the Toyota Production System.

Dynetics Technical Services – Huntsville, AL

Support DTS Aerospace & Defense Systems initial “Start-Up” of Hyper Sonic Glide Body operations. Assist with factory layout and station development to meet program goals & objectives. Support DTS process improvement efforts for low-rate production of HGB value streams. Performing observations and time studies of initial assembly operations to support future improvement efforts. Active Security Clearance

Lockheed Martin Missiles and Fire Control – Ocala, FL

Support LM Aerospace & Defense Systems process improvement efforts for Low Volume/High Mix Missiles and Fire Control Value Streams. Assist in the Stand-Up and implementation of SAP ERP System with emphasis on Production Material Review of Non-Conformances & Dispositions. Collect & Analyze Data, Develop Standards and Lead CI Projects to improve 1st Pass Test Yields and overall Contract Position (Lead Time & Throughput).

Plexus – Neenah, WI

Support Plexus Aerospace, Defense & Medical Systems process improvement efforts for Low Volume/High Mix Contract Electronic Manufacturing Value Streams. Identified & Lead CI Projects for (6) Electrovert Wave & (5) ERSA Select Soldering cells. Developed Product Family Matrix based on process requirements: Solder (TL/LF), Flux (WS/NC), Profiles (PCB layers) and Tooling (Pallets). Reconfigured equipment to accommodate alloy demand, upgraded equipment to accommodate multiple flux requirements, consolidated multiple monthly WO, purchased additional tooling based on demand, scheduled work based on process needs, established (4) station hand-load cells, developed optimizing/balancing app. & off-line set-up team. Reduced # of changeovers required by 50%, reduced changeover time by 60% and processing time by 25%.

Sanmina-SCI – Huntsville, AL

Support SCI Defense Systems process improvement efforts for Low Volume/High Mix Contract Electronic Manufacturing Value Streams. Developed Current State Floor Plan with spaghetti flow of each product based on shop floor traveler and routings with wait time, cycle times and distance traveled. Developed Product Family Matrix based on Process Requirements: RMA, Water Soluble, No Clean or Lead Free. Developed Process Requirements based on Technology required: SMT Single Side, SMT Double Side, PTH, Standard Wave Soldering vs. Selective Soldering, AOI, X-Ray, ICT & FCT. Future State now accommodates six continuous one-piece flow lines (3 SMT & 3 PTH) and 12 final assembly box-build/customer focused cells. Future State has reduced floor space requirements by 25% & lead time by 50%.

Electro Switch/Digitran – Rancho Cucamonga, CA

Set-up Initial Lean Management System process improvement efforts for both the Digital & Rotary Low Volume/High Mix Aircraft Switch value streams. Identify and Lead CI projects for Materials, Engineering, Manufacturing, Quality Control and Facilities. Developed plan based on current state eVSM, cycle time, customer takt time and order history. Set-up min/max for all raw parts and pull system for finished parts. Reduce cycle times by 50% with Standard Work & Universal Setups. Increased FPT yields from 70% to 85% utilizing FMEA & Real Time Feedback. Developed KPI for OEE, OTD, IT, FPTY and Build to Schedule.

AVCORP Composite Fabrication – Gardena, CA

Support Lean Management System process improvement efforts for both the Lockheed F-35 & Boeing 787 High Volume/High Mix Fiber Composite Fabrication value streams. Identify and Lead CI projects for the ATL, AFP, Gerber, Hand-Layup, Autoclave, CNC Machining and NDT centers. Setup recovery teams based on cross functional support and kaizen bursts from current state value stream map to drive rapid improvements using TQM, TPS, LSS & FMEA. Updated Automatic Fiber Placement KPI to lbs./hr vs. inches/hr and revised programs to take full advantage of bi-directional placement of fiber. (4) Machine production schedule was revised to meet customer demand and actual shipping mix/volume.

Consolidated Container Corp. – Atlanta, GA

Support Lean Management System process improvement efforts for both the HDPE & PET resin High Volume/High Mix (14) Plant Western Region Blow Molding value streams. Identify and Lead CI projects for the Shuttle, Reciprocating and Wheel platforms to meet customers Overall Equipment Effectiveness Glidepath. Lead, Teach and Mentor each facility staff on deployment and execution of OEE, Layered Audits & Daily Team Maintenance plan based on Best In Class Standards and Plant Value Creation Analysis.

Parker Hannifin, Parker Aerospace CSD – Irvine, CA

(Brown Field Factory Re-Organize) Support Lean Management System process improvement efforts for the Cargo, Commercial, Electronics, Fighter & Helicopter Low Volume/High Mix Hydraulic Valve value streams. Identify and Lead CI projects in the CNC Machining, Assembly & Test areas of each cost center. Developed & executed facility plan for one-piece flow based on part family matrix. Reduced overall footprint and relinquished 10,000 sq. ft. of floor space for the addition of two FCSIL

WS Packaging Group – Fullerton, CA

Support Lean Management System process improvement efforts for both the Prime & Multi-Vision construction Low Volume/High Mix Narrow Web Flexographic Printing multi-plant value streams. Developed Current State eVSM, Floor Plan (Spaghetti Flow), Capacity Analysis and Staffing plan to assess capability to meet company goals & objectives. Perform Kaizen events for TPM, VRK, SMED, FMEA & Model Cell with Standard Work. Developed KPI for Overall Equipment Effectiveness, On Time Delivery, Inventory Turns, First Pass Yield and Build to Schedule. Implemented solutions to standardize equipment by width, stations and process (UV/WB). Reduced initial set-up time, make ready footage and overall MSI. Optimized Ink Mixing area with new layout and improved communication. Restructured Kitting area based on Takt Time of Press requirements to One Piece Flow. Initial impact of $6M/yr, Future State with consolidation should be in excess of $20M/yr.

Northrop Grumman Aerospace Corp. – El Segundo, CA

Support Affordability process improvement efforts for the F/A-18, F-35 & Global Hawk High Volume/High Mix Fiber Composite Fabrication and Integrated Assembly Line value streams. Setup recovery teams based on cross functional support and kaizen bursts from current state value stream map to drive rapid improvements utilizing TQM, TPS, LSS & FMEA. Identified and lead projects for Kitting, Simple Skins, Complicated Skins, Ducts, ATP, Autoclave, Breakout, CNC PMM & AUSS areas within composite center, as well as, Global Supply Chain and Goods Movement ASRS Put-a-ways, Picks, Shadow Boxes and Milk Runs. Doubled ASRS Capacity by updating operating system and matching storage locations with shadow box pick list. Reduced Automatic Tow Placement (Viper 1200) cycle time from 12 to 3.5 days by addressing all minor defects, optimizing programs, training operators & technicians to standard work & pre-fight checklist. Project Awarded NGC President’s Award.

Futronix, Inc. - Homosassa, FL

Oversee Business and Operational functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) of Bankrupt 300/EP vertically integrated multi-plant operation. Set-Up Initial Lean Management System to support Med Volume/Med Mix Contract Electronic, Wire & Cable, Plastic Injection Molding, Metal Stamping, CNC Machining and Box-Build Manufacturing Value Streams. Facilitate full utilization of ERP/MRP System to capture shop floor & warehouse data. Established Integrated Product Support Teams to drive customer focused factories. Re-Layout Facility to allow one-piece continuous flow manufacturing. Facilitate New Product Introduction, Map and Define Processes and Product Flow utilizing Process Control Manual. Teach, Mentor and Train Production Associates, Machine Operators, Technicians, Engineers and Support Staff in TQM & TPS. Utilized LSS & FMEA Quality Control Techniques and Concepts to study & reduce variation in process. Re-established business with customer base and removed from Bankruptcy. Company Sold & Fluorescing today, Over $40M annually.

Boeing, IDS, SOF, Aerospace - Crestview, FL

Developed Initial Hanger Layout for (4) AC-130 Gunship’s, equipment, tools and personnel utilizing 3P process. Developed, maintained and optimized Bar Chart’s for each aircraft, employing lessons learned, reducing lead-time by six months for each. Delivered & Presented Earn Value Metrics for Planning and Manufacturing to Sr. Management. ($540M program)

Mid-South Electronics - Gadsden, AL (1999 to 2003)

● Director of Operations: (Brown Field Factory Re-Organization) Oversee Business and Operational functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) of $300M/600 EP vertically integrated multi-factory operation. Developed and Set-Up Initial Lean Management System to support Med Volume/Med Mix Contract Electronic, Wire & Cable, Plastic Injection Molding, Metal Stamping, CNC Machining and Box-Build Manufacturing Value Streams. Facilitate Full Utilization of Oracle ERP/MRP System with Shop Floor Data Collection & Warehouse Management Modules. Established Integrated Product Support Teams to drive customer focused factories. Re-Layout Facility to accommodate 24 One-Piece Continuous Flow lines. Facilitate New Product Introduction, Map and Define Processes and Product Flow utilizing Process Control Manual. Teach, Mentor and Train Production Associates, Machine Operators, Technicians, Engineers, Supervisors, Managers and Company Leadership on TQM, TPS, LSS & FMEA to drive improvements. Review machine operating efficiency reports, downtime data and 1st pass test yield to establish OEE metric. Studied overall mean time between failures to develop predictive & preventative maintenance schedules on machines, feeders and peripheral equipment.

Qualcon – Flowery Branch, GA (1995 to 1999)

● Manufacturing / Engineering Mgr.: (Green Field Factory Start-Up) Set-Up initial Lean Management System utilizing TQM, LSS, FMEA and the Toyota Production System to established One Piece Flow of Low Volume/High Mix Contract Electronic Manufacturing Value Stream. Developed Floor Plan, Ordered, Installed & Tested assembly equipment. Develop & Optimize assembly equipment programs, reflow oven and wave solder profiles. Facilitate New Product Introduction, Map and Define Processes and Product Flow utilizing Process Control Manual. Teach, Mentor and Train Production Associates, Machine Operators, Technicians, Engineers and Company Leadership in TQM & TPS. Introduced LSS & FMEA Quality Control Techniques and Concepts to study variation in process. Developed Initial Quality Manual, Procedures, Work Instructions and Forms per ISO9001 and IPC610 Rev. C Standards. ISO9001 Registration Received 08/98

Vittel Technologies – Norcross, GA (1991 to 1995)

● Sr. Manufacturing Engineer: (Green Field Factory Start-Up) Set-up initial Lean Management System utilizing TQM, LSS, FMEA and the TPS to established One Piece Flow of Low Volume/High Mix Contract Electronic Manufacturing Value Stream. Developed Floor Plan, Ordered, Installed & Tested assembly equipment. Develop & Optimize assembly equipment programs, reflow oven and wave solder profiles. Order SMT Solder Paste Stencils, Waves Solder Pallets & other tooling as required. Review machine operating efficiency reports, downtime data and 1st pass test yield to establish OEE metric. Studied overall mean time between failures to develop predictive & preventative maintenance schedules on machines, feeders and peripheral equipment. Teach, Mentor and Train Production Associates, Machine Operators, Technicians and Engineers on the Toyota Production System. Develop Initial Quality Manual, Procedures, Work Instructions and Forms per ISO9001 and IPC610 Rev. C Standards. ISO9001 Registration Received 09/95

AVEX Electronics – Huntsville, AL (1989 to 1991)

● Manufacturing Engineer: (Brown/Green/Brown Field) Worked with team to develop initial Lean Management System utilizing TQM, LSS, FMEA and the Toyota Production System to established (10) One Piece Flow High Volume/Low Mix Contract Electronic Manufacturing Value Streams. Teach, Mentor and Train (50) Machine Operators and (15) Technicians. Develop & Optimize SMT & PTH machine placement programs, reflow oven and wave solder profiles. Conduct Time Studies for machine set-up, changeover and performance. Order SMT Solder Paste Stencils, Waves Solder Pallets & other tooling as required. Develop Work Instruction and Process Control Documents per ISO9001 and IPC610 Rev. C Standards. Review machine operating efficiency reports, downtime data and 1st pass test yield to establish Overall Equipment Effectiveness metric. Studied overall mean time between failures to develop predictive & preventative maintenance schedules for machines, feeders and peripheral equipment. Played Key role in support of Company expansion to (3) facilities/locations and contraction to single facility with Green Field Set-Ups and Brown Field re-arrangements.

SCI – Huntsville, AL (1987 to 1989)

● Manufacturing Technician: (Green Field Relocation) Develop & Optimize SMT & PTH machine placement programs, reflow oven and wave solder profiles. Conduct Time Studies for machine set-up, changeover and performance. Review machine operating efficiency reports, downtime data and 1st pass test yield to establish Overall Equipment Effectiveness metric. Perform scheduled PM’s and trouble-shoot/repair equipment as required. Study mean time between failures to develop predictive & preventative maintenance schedules on machines, feeders and peripheral equipment and Teach, Mentor and Train (30) Machine Operators in support of (10) High Volume/Low Mix Contract Electronic Manufacturing Value Streams. Played Key Role in Plant Re-Location, Shut-Down, Packed & Skidded Equipment. Un-Packed, Located, Set-Up, Turned On & Tested in New Location.

SCI – Huntsville, AL (1985 to 1987)

● Machine Operator: Set-Up & Operate SMT, PTH, Reflow Oven, Wave Solder, Wash and other equipment as assigned following Standard Operating Procedures. Collect data and fill in forms and charts as required. Perform Daily Preventative Maintenance as required following standard checklist per ISO9001 Standard in support of High Volume/Low Mix Contract Electronic Manufacturing Value Streams.

SCI – Huntsville, AL (1984 to 1985)

● Production Associate: Perform all duties as assigned to support High Volume/Low Mix Contract Electronic Manufacturing Value Streams. Duties included material handling, component prep, mechanical assembly, hand load, burn-in, in circuit and functional test of circuit card assemblies.

BS Mfg. Eng. Tech. Jacksonville St. University 1989

AS Electronics NW Shoals Community College 1987

HS Diploma Russellville High School 1984

Program/Project Mgt. 2012

Knowledge Capture/Mgt. 2011

OHSAS18001/ISO45001 2010

IS014001/ISO50001 2009

Operational Excellence 2001

Six Sigma Black Belt 1998

ISO9000 Lead Assessor 1996

Six Sigma Certification 1994

ISO9001 Certification 1993

Lean Mfg. Certification 1992

ISO9001 Internal Auditing 1991

ISO9001 1990

SPC 1986

TQM 1985

Software

Maximo, M2M, SAP, Oracle, Sage, 4th Shift, eVSM, Microsoft Word, Excel, Power Point, Access, Outlook, Project & Visio, CAD, Solid Works, Circuit-CAM, Uni-CAM, Cimbridge, Valor, MOLE, Kick, Fuji, Panasonic, UIC, Siemens, Philips, Mini-Tab, Master CAM, CNC, 3-D Printing, ICT GenRad, HP & Teradyne.

References

Cameron Konkle Plexus 920-***-**** 1 Yr. Eng.

Gus Marquardt Plexus 920-***-**** 1 Yr. Eng.

Marion Zubrick SCI 256-***-**** 2 Yr Eng.

D.M. Jones Avcorp 310-***-**** 4 Yrs. GM

Justin Below Parker 210-***-**** 7 Yrs. Lean

Eric Victor Parker 949-***-**** 7 Yrs. Lean

Laszlo Szilagyi NGC 714-***-**** 10 Yrs. Eng.

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