Production Planning Process Improvement

Rodney Lamont Bullock

**** ****** ***** *** ***

Forestville, MD 20747

202-***-**** (Work Cell)

202-***-**** (Cell)

E-Mail – ******.*******@***.***

E-Mail – *********@*****.***

SUMMARY: A manufacturing professional with 20+ years of experience in the areas of Production Planning & Control, Production, Engineering, Quality, Lean Manufacturing, Cost Reduction, Inventory, MRP/ERP systems, recruiting/staffing, and Process Improvement (Kaizen). A proven leader in Lean/Sigma projects, Kaizens, supplier development, associate development, production-planning & control, management/supervision, and customer satisfaction. Effective communicator, capable of explaining technical and financial issues on all levels of the organization.

PROFESSIONAL EXPERIENCE:

United States Bureau of Engraving and Printing Washington, DC 04/21 – Present

Supervisory General Engineer (Capital Equipment Division Manager) GS-0801-14

40 Hours/Week

Technical Management Duties (75%)

Supervise personnel, track and report to senior management the status of acquisition and implementation of new equipment, processes, and systems. This includes generating cost/benefit and life cycle cost estimates for proposed new capital acquisitions in conjunction with the Offices of Financial Management and Acquisition. In doing this, the incumbent must work closely with Office of Currency Manufacturing at both facilities to understand current and future needs. The incumbent ensures all acquisitions are coordinated with and address the requirements of Facilities, Quality, CIO, Environmental and Safety, Security and Compliance.

Extensive knowledge of industrial equipment specifications and manages employees to successfully develop these specifications applied to BEP needs. Further, the incumbent is experienced in writing and executing test plans based on the equipment specifications.

Direct/lead others to develop and track project plans including costs, milestones, schedules, and resource requirements. Monitors progress of the work efforts and facilitates the resolution of problems to assure the work progresses to schedule.

Provide technical leadership and manage/mentor engineers in problem definition and solution using analytical, quantitative, and systematic problem-solving skills. This includes design of experiments and test plans to verify the problem solution.

Supervise personnel to analyze manufacturing and production related equipment, systems and processes that routinely exhibit less than acceptable productivity, quality, and/or workmanship and initiates appropriate corrective action. The incumbent reviews and approves analytical test plans, reports and recommendations made by the staff for completeness and effectiveness to meet BEP manufacturing requirements.

Supervise personnel to design, test, implement and monitor inspection and verification machinery, off-line sampling or on-line, to support high quality manufacturing of currency.

Supervise personnel to define and implement metrics and performance indicators to gauge the effectiveness of existing manufacturing processes and production equipment. This includes conducting tests or collecting and analyzing data to verify the accuracy of the information.

The division manager formulates, maintains and adjusts long-range plans for the development and implementation of equipment and process improvement programs; taking into account currency demand, continuation of operation, introduction of new features and designs, and manufacturing process changes.

Act as a customer liaison to internal and external Bureau customers and will be the focal point for equipment acquisition and replacement planning activities.

Work closely with and advise the Offices of Technology Development and Product Development on acquisition planning, equipment capabilities and manufacturing processing for changes to and new features and designs.

Work closely with management in the Offices of Quality and Currency Manufacturing to understand the product standards to generate new inspection systems requirements for verification on current and future equipment.

Aware of the latest developments in advanced manufacturing, inspection technology, and production techniques and proposes ways to explore and implement these developments into BEP operations when cost effective.

Supervision (25%)

Plan work to be accomplished by subordinates, set and adjust short-term priorities, and prepare schedules for completion of work

Assign work to subordinates based on priorities, selective consideration of the difficulty and requirements of assignments, and the capabilities of employees

Evaluate work performance of subordinates

Give advice, counsel, or instruction to employees on both work and administrative matters

Interviews candidates for positions in the unit; recommend appointment, promotion, or reassignment to such positions

Hear and resolve complaints from employees, referring group grievances and more serious unresolved complaints to a higher-level supervisor or manager

Effect minor disciplinary measures, such as warnings and reprimands, recommending other action in more serious cases

Certify staff time and attendance records

Determine operating budget requirements

Establish goals, objectives, and plans for the Division

Determines resources needed for the successful accomplishment of the work

Determines training needs and implements training plans

Establish employee performance plans and Individual Development Plans. Conducts mid-year and end-of-year employee performance reviews and appraisals

Coordinate the activities of the Division with other organizations

Ensure that staff members complete all BEP mandatory training requirements

Review technical reports prepared by staff members

Hiring manager for the division

United States Bureau of Engraving and Printing Washington, DC 09/20 – 04/21

General Engineer (Sr. Quality Engineer) GS-0801-13

40 Hours/Week

A consultant and expert advisor to Bureau components' efforts to continually improve engineering and manufacturing quality performance.

Plan, coordinate, and execute the quality program necessary to ensure products consistent with engineering specifications and customer requirements.

Formulate and maintain engineering and related quality standards that conform to customer requirements.

Develop and or ensure that product quality standards are established, approved, understood, implemented, and adhered to by all departments.

Evaluate process equipment capabilities to ensure product conformance to established requirements. Evaluates test results in accordance with preliminary standards; obtains test samples; prepares draft standards; obtains higher authority approval of draft standards; trains employees in use of quality standards; and, evaluates usefulness of quality standards.

Ensure deliverable products meet customer requirements. Investigate emerging and or current quality problems associated with final product quality verification.

Performs root-cause analysis and other problem solving activities to identify effective corrective actions and engineering process improvements. Investigates and initiates the response to customer complaints. Conduct problem solving using statistical techniques. Develop sampling plans, statistical process control, capability analysis, designed experiments, etc.

Work collaboratively with manufacturing and other technical components to implement engineering quality improvement projects.

Develop, implement and document standard operating procedures. Establishes conditions parameters for process control, process improvement, testing and inspection.

Evaluate and advise on the feasibility of new technology and state-of-the-art equipment for incorporation into existing engineering systems and equipment. Assists manufacturing with validation of new equipment prior to approval for production.

Analyze and investigate adverse quality trends or conditions. Initiates and develops corrective and preventive actions. Leads cross-functional teams on implementing process changes, quality improvements, spoilage reductions, on-line inspections, and or other investigations projects to ensure product quality improvement.

Serve as a facilitator for engineering quality improvement teams or similar activities to promote improved quality systems throughout the BEP.

Participate on product design teams to ensure process capability and capacity. Provide quality advice and technical assistance on the production floor.

Support BEP wide efforts to improve the Quality Assurance System from an engineering standpoint and prepares reports and summarizes the results of testing for BEP managers and executives.

Support the Currency Quality Assurance efforts as a team leader, team member, and or subject matter expert as requested. Report at the Monthly Quality Meeting current status on quality engineering standards development, final currency fitness for use and emerging quality problems.

Utilizes the Monthly Quality Meeting reports to provide summary input in to the Executive Management Review.

Utilizes LEAN Six Sigma an integrated management approach, including communication tools, decision making, charting, team building, and problem solving.

Adheres to the organization's strategic plan, mission, vision, and values that are communicated to the team.

Securely stores and maintains accountability for samples or security products collected for studies and other assignments. Abides by safety protocols for all component areas.

Performs other duties as assigned.

United States Bureau of Engraving and Printing Washington, DC 04/20 – 8/20

Supervisory Industrial Engineer NTE Detail Promotion, GS-0896-14

40 Hours/Week

Division Quality Manager for BEP DC facility (Detail promotion)

Provided technical direction, supervision and coordinated the Quality Engineering staff program operations within the Office of Quality.

Determined the scope of projects, assigns work to staff members, determines appropriate manpower utilization resources for all projects, coordinating, and assures compliance with completion dates, and revises work for conformance to governing laws, policies, and standards. Exercises a range of supervisory responsibilities over professionals at the GS-13 grade level and below.

Assigns work based on priorities and selective consideration of the demands of the work and the capabilities of employees.

Established performance standards and evaluates subordinates' performance. Advised and instructed employees on both work and administrative matters.

Interview candidates for positions in the Division and recommends such actions as appointments, promotions, reassignments for such positions; hears and resolved complaints from employees, makes recommendations to resolve grievances; effects minor.

Developed Jr. General Engineers (Quality)

Maintained quality standards that conform to customer requirements.

Carries out quality improvement related assignments from the Chief of the Office of Quality.

Provide weekly status report of all activities to department chief.

Guide engineers through difficult situations encountered during CAPA activities.

Served as a facilitator for quality improvement teams, quality management training workshops, focus groups, or similar activities to promote improved quality systems through-out the BEP. Coaches team leaders and members to develop problem-solving techniques.

Analyze and investigate adverse quality trends or conditions. Initiates and develops corrective and preventive actions. Assembled and lead cross-functional teams on implementing process changes, quality improvements, spoilage reductions, on-line inspections, and or other investigations projects to ensure product quality improvement.

Monitor multi-plant quality assurance initiatives providing guidance and assistance to ensure they are carried out consistent with BEP strategic goals. Recommend improved, strategic, measurable, and sustainable solutions, as well as, identify further opportunities for improvement.

Develops, implements, and documents standard operating procedures and conditions for process control, process improvement, testing, and inspection.

Support ISO9000 2015 activities.

Performs other duties as assigned.

United States Bureau of Engraving and Printing Washington, DC 03/19 – 04/20

General Engineer (Sr. Quality Engineer) GS-0801-13

40 Hours/Week

A consultant and expert advisor to Bureau components' efforts to continually improve engineering and manufacturing quality performance.

Plan, coordinate, and execute the quality program necessary to ensure products consistent with engineering specifications and customer requirements.

Formulate and maintain engineering and related quality standards that conform to customer requirements.

Develop and or ensure that product quality standards are established, approved, understood, implemented, and adhered to by all departments.

Evaluate process equipment capabilities to ensure product conformance to established requirements. Evaluates test results in accordance with preliminary standards; obtains test samples; prepares draft standards; obtains higher authority approval of draft standards; trains employees in use of quality standards; and, evaluates usefulness of quality standards.

Ensure deliverable products meet customer requirements. Investigate emerging and or current quality problems associated with final product quality verification.

Performs root-cause analysis and other problem solving activities to identify effective corrective actions and engineering process improvements. Investigates and initiates the response to customer complaints. Conduct problem solving using statistical techniques. Develop sampling plans, statistical process control, capability analysis, designed experiments, etc.

Work collaboratively with manufacturing and other technical components to implement engineering quality improvement projects.

Develop, implement and document standard operating procedures. Establishes conditions parameters for process control, process improvement, testing and inspection.

Evaluate and advise on the feasibility of new technology and state-of-the-art equipment for incorporation into existing engineering systems and equipment. Assists manufacturing with validation of new equipment prior to approval for production.

Analyze and investigate adverse quality trends or conditions. Initiates and develops corrective and preventive actions. Leads cross-functional teams on implementing process changes, quality improvements, spoilage reductions, on-line inspections, and or other investigations projects to ensure product quality improvement.

Serve as a facilitator for engineering quality improvement teams or similar activities to promote improved quality systems throughout the BEP.

Participate on product design teams to ensure process capability and capacity. Provide quality advice and technical assistance on the production floor.

Support BEP wide efforts to improve the Quality Assurance System from an engineering standpoint and prepares reports and summarizes the results of testing for BEP managers and executives.

Support the Currency Quality Assurance efforts as a team leader, team member, and or subject matter expert as requested. Report at the Monthly Quality Meeting current status on quality engineering standards development, final currency fitness for use and emerging quality problems.

Utilizes the Monthly Quality Meeting reports to provide summary input in to the Executive Management Review.

Utilizes LEAN Six Sigma an integrated management approach, including communication tools, decision making, charting, team building, and problem solving.

Adheres to the organization's strategic plan, mission, vision, and values that are communicated to the team.

Securely stores and maintains accountability for samples or security products collected for studies and other assignments. Abides by safety protocols for all component areas.

Performs other duties as assigned.

United States Mint (Head Quarters) Washington, DC 02/16 – 3/19

Production Planning & Control Specialist GS-1101-13

40 Hours/Week

Lead weekly meeting with Sales and Marketing (SAM) in all matters related to production and delivery of numismatic and bullion products

Create Master Planning Schedule (MPS) revisions and execute getting the changes approved by Associate Director of Manufacturing and the Associate Director of Sales and Marketing

Created SOP for Master Planning Schedule (MPS) Change Request

Developed 2017 Master Planning Schedule (MPS)

Developed 2018 Master Planning Schedule (MPS)

Developed 2019 Master Planning Schedule (MPS)

Developed 2020 Master Planning Schedule (MPS)

Maintained and managed the 2016 Master Planning Schedule (MPS) for Numi and Bullion Products on a daily basis.

oResults:

100% On-Time Delivery for Numi and Bullion Products for FY 2016

2016 NPS Commemorative Programs returned a ROI of 2+Million$

Developed 2018 Master Planning Schedule (MPS) for Numi and Bullion Products

Issue and maintain weekly schedule for die shop

Calculate the number of required dies per item code to meet MPS needs

Issue and maintain weekly Master Planning Schedule (MPS) Status Report for Numi and Bullion Products. Key tool for week to week sales, production, inventory, and shipping performance, etc.

Monitor daily back order and low inventory items

Serve as COR for a primary vendor. 14 Million Dollar Project/Contract budget.

oEnsure vendor is compensated. Enter receipts for final payment

oMonitoring quality and timeliness of delivery

oInitiate and execute task for incremental funding

oIncorporation of change orders

oIssue of stop work orders

oPreparation of rate and cost adjustments

oLead efforts in disposition of quality issues

Provide data and reports as required/requested by management

Develop production schedules for US Mint products

Monitoring and reporting on production at Mint field site. Monitor actual production against the schedule.

Implementing systems to help streamline the production planning process

Communicate production requirements to Mint field sites

Maintaining critical production information including: finished products & coins inventories, current & historical production figures, work in process, and production reports necessary to the daily management of numismatic coin production

Assists the Supply Management group in monitoring the volume of condemned coins and blanks generated at the field facilities.

Point of contact to the Sales and Marketing (SAM) unit, and represents the United States Mint in all matters related to the production and delivery of numismatic and bullion products.

Develop the Master Planning Schedules (MPS) for numismatic products produced at the United States Mint's four production facilities, including the establishment of customer availability dates for all numismatic products produced by the Mint.

Plan finished product inventories and coordinate all efforts necessary to ensure numismatic products are available to meet customer requirements and the strategic requirements of the United States Mint.

H&R Block Capitol Heights, MD 01/16 – 03/16

Client Services Professional

Provide customer service to tax client’s

Set appointments

Assist in preparing taxes

Order and maintain office supplies

Actively participate in marketing activities to gain new client’s

Assist office manager and tax preparers when needed

Reason for leaving: Seasonal position

H&R Block Capitol Heights, MD 01/15 – 04/15

Client Services Professional

Provide customer service to tax client’s

Set appointments

Assist in preparing taxes

Order and maintain office supplies

Actively participate in marketing activities to gain new client’s

Assist office manager and tax preparers when needed

Reason for leaving: Seasonal position

AMESBURY PRODUCTS Statesville, N.C. 07/13 – 12/13

Senior Quality/Process Engineer [Hardware Products]

Primary contact between customers/suppliers and the facility

Provided weekly and monthly Quality Metrics Reports (KPIs). In addition, provided corrective/preventive action plans with ROI to management staff.

Led corrective action activities both internally and externally for the entire facility

Led and completed internal audits per level 2 procedure requirements

Implemented c=0 sampling plans in areas with high reject levels

Provided retraining for internal auditors

Responsible for calibration. Ensured all calibration items were up to date. In addition, justified the purchasing of new gages through scrap cost and Gage R&R studies.

Actively led and participated in KAIZEN events.

Participated in new/current product design reviews.

Led process validation activities.

Created and implemented PROCESS FLOWS, PFMEAs, and CONTROL PLANS for assigned processes.

Approve/disapprove supplier PPAP submissions. Key player in supplier development.

Reduced MRB cycle time from 2 weeks to 48 hours

Reason for leaving: Contract position. Contract hours expired

MIRACLE HANDS LANDSCAPING/JANITORIAL SERVICE Greensboro, NC 10/11 – 01/15

Supervisor/General laborer

TELEFLEX MEDICAL Asheboro, N.C. 09/10 – 10/11

Senior Quality/Process Engineer [Medical Device Kits]

Led CAPA project that reduced printing errors by 85%.

Clean room experience and sterilization process experience (EO ethylene oxide process).

Provided monthly Quality Metrics Reports (KPIs) for management staff.

Reduced incoming inspection sampling plans on specific purchased components that resulted in significant cost savings.

Completed nonconformance reports (NCs) using Pilgrim software.

Led production personnel in problem solving activities.

Trained all associates in various segments of quality systems. Ex. ISO13485, QSR

Provided quality support to assigned Business Unit.

Review and approve sample kits.

Actively led and participated in value stream exercises.

Participated in new/current product design reviews.

Led process validation activities.

Perform risk assessments. In addition, created PFMEAs for assigned processes.

Review and approve ECRs/ECOs.

Approve/disapprove supplier PPAP submissions. Key player in supplier development.

Reason for leaving: Layoff/Reduction in workforce

HONEYWELL INTERNATIONAL by WH Salisbury Charleston, S.C. 09/08 – 05/09

Senior Quality/Process Engineer [Insulated Rubber Electrical Glove Manufacturer]

Led latex team in increasing yields from 20% to 70% in 3 months.

Conducted all quality audits prior to 3rd party audits. The management representative for ISO9001 certification at the Charleston, SC facility.

Created and implemented standard work instructions & boundary samples for visual inspectors.

Calculated plant PPM for customer returns weekly and entered data into the corporate dashboard

Updated & provided yield reports for weekly latex production line performance meetings.

Identified areas of improvement in the quality system. Prepared cost of quality reports. Provided solutions/suggestions to troubled areas.

Led root cause and countermeasure activities.

Co-led Inspection & Tests Kaizen that increased inspection flow by 30%.

Created PFMEA and Control Plan for Latex Lineman area. In addition, trained hourly personnel in the use of these tools.

Assisted associates with lean project preparation and presentations.

Led material review board (MRB)/Customer returns process.

Developed BOMs and routings using Oracle MRP/ERP system

Approve/disapprove supplier PPAP submissions. Key player in supplier development.

Reason for leaving: Contract position. Contract hours expired

JACOBSEN via AEROTEK Contract Engineering Charlotte, N.C. 11/07 – 09/08

Supplier Quality Engineer [Turf Equipment Manufacturer]

Reviewed and approved/rejected supplier PPAP submissions to Jacobsen for new and existing components.

Led quality system audits at supplier locations.

Led print review meetings between suppliers and Jacobsen design engineers to resolve technical issues.

Provided quality performance data for suppliers to Jacobsen’s purchasing department in order to calculate supplier’s Scorecard.

Identified areas of improvement in the quality system to Senior Leadership team. In addition, I supplied potential cost effective solutions to the Senior Leadership team.

Led root cause and countermeasure activities with internal quality team.

Coordinated lab testing activities for various supplier components and review/approve results.

Supplier quality engineer champion for Jacobsen’s new greens mower project.

Developed BOMs and routings using Oracle MRP/ERP system

Reason for leaving: Contract position. Contract hours expired

CHARLOTTE AREA TRANSIT (CATS) Charlotte, N.C. 11/05 – 11/06

Quality Assurance Engineer [Light Rail]

Key role in developing and implementing a quality system for CATS that is compliant to ISO9000 standards, American Public Transportation Association (APTA) standards, and Federal Transit Authority (FTA) standards.

Led internal, supplier, and subcontractor quality system audits.

Coordinated/conducted first article inspections at supplier facilities for light rail system components

Reviewed and approved contractors'/consultants' quality control program plans for conformance to CATS requirements.

Led light rail operations staff in establishing quality assurance requirements for start-up activities (Greenfield Project)

Technical and quality assurance representative for factory acceptance test of light rail components.

Developed Total Preventative Maintenance Program with Rail Maintenance Manager

Developed SOPs for various processes and customers.

Assisted CATS procurement team by providing QA standards in the acquisition of light rail vehicles.

Led operations team in developing Process Failure Mode and Effects Analysis (PFMEA)

Knowledgeable of light rail components and rail systems components

Reason for leaving: Returned to manufacturing

DANAHER TOOL GROUP [Hand Tools] Gastonia, N.C. 5/00 - 5/05

Quality/Manufacturing Engineering Manager

Primary contact between the plant and the customer.

Maintained all aspects of the quality system (ISO9001). ISO coordinator for Gastonia plant. Developed SOPs.

Led TPI kaizen that reduced paper transactions by 50%.

Led Six Sigma project resulting in $300,000.00 annual savings in wet vibratory area.

Developed 3rd level quality policy deployment and quality KPI objectives for the Gastonia facility. Developed and implemented cost of poor quality (CPQ) for the Gastonia facility to ensure the correct failures were being addressed by PPM and cost.

Reduced internal PPM levels from 80,000 PPM to 30,000 PPM.

Managed quality & manufacturing engineers and 12 quality auditors.

Led teams conducting process capability studies. Developed SOPs for various processes and customers.

Led variation reduction kaizen event that reduced PPM level by 50% in vibratory area.

Assisted marketing in new product launches from the plant level by providing APQP documentation and test(s) data.

Dual responsibilities of Area Manager and Quality Manager

o Responsible for leadership and development of more than 180 hourly and salaried employees.

o Led plating, vibratory, and heat treat areas.

o Primary contact for customer complaints and corrective action responses.

o Responsible for hiring and developing new talent within the departments.

o Full understanding of Danaher Business System/Toyota Production System.

oResponsible for Master Schedule for Process Sub-plant area using Oracle MRP/ERP system. Hands-on working experience managing and developing production schedules for finished goods and sub-assemblies for production in an industrial manufacturing environment.

oHands on working experience Planning and Scheduling using Material Resource Planning / Enterprise Resource Planning systems (MRP/ERP) in an industrial manufacturing environment.

oFull working knowledge on how MPR/ERP systems work.

oDeveloped BOMs and routings using Oracle MRP/ERP system

Approve/disapprove supplier PPAP submissions. Key player in supplier development.

Reason for leaving: Restructuring in management

INVENSYS [Tier 1 Automotive] Shelby, N.C. 10/99 – 5/00

Senior Current Product Engineer

Responsible for the investigation, containment and resolution of customer complaints and/or returns.

Effectively communicated with the customer quality requirements associated with assigned product areas.

Evaluated suspect and nonconforming product and determine disposition. MRB leader.

Performed design of experiments to resolve switch point problem with new developed switch.

Reduced cost of quality ($20,000 annual savings) by negotiating with customer instead of making expensive sorting trips.

Developed meaningful SPC methods for critical characteristics on assigned product lines.

Led and coordinated cross-functional teams to resolve customer issues.

Reduced excessive processes for internal cost savings.

Approve/disapprove supplier PPAP submissions. Key player in supplier development.

Reason for leaving: Career growth offered with Danaher

ASMO North Carolina [Tier 1 Automotive] Statesville, N.C. 6/98 – 10/99

Senior Quality/Process Engineer

Interfaced directly with customer on courtesy visit for monthly line accumulations. Primary contact for customer issues.

Developed SOPs for new and existing lines.

Recovered over $600,000.00 lost in packaging.

Reduced warranty returns from major customer by 50%.

Reduced overall PPM from 80 to 10 during 1999 Model Year.

Responsible for the overall quality of product and total customer satisfaction.

Provided customers with analysis reports of returned product.

Collected and provided necessary Production Part Approval Process (PPAP) documentation to customers.

Consulted customer ensuring quality is built into products during the design and production phases of new product – eliminating (rework, redesign )

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