Six Sigma Product Introduction

Stanley MJ Baker

*** ****** **. ● Madison, AL ***58

● C: 256-***-****

*******.*.*****@*******.***

www.linkedin.com/in/stanley-baker-opex-lean-sensei

Operation Excellence Leader with 30 plus years of 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 ● POU Stock/Vending

● Visual Management ● Continuous Improvement

● DMAIC ● Waste Stream (Green)

● Metrics: 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

● Project Planning & Engineering ● Quality Assurance Control & Standards

● Budget Planning & Administration ● ERP/MRP Project Management

● Program Management (PMBOK) ● Production Control & Scheduling

● Supply Chain Management ● ISO9001, ISO14001 & AS9100

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 eliminate 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 (April 2003 – Current)

● 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 (Contract)

● Principle Engineer /Lean Sensei: Support DTS Aerospace & Defense Systems initial “Start-Up” of Hyper Sonic Glide Body operations. Assist with factory layout and station development to meet required takt time. 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.

Lockheed Martin Missiles and Fire Control – Ocala, FL (Contract)

● OpEx/ Lean Sensei: 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 (Contract)

● OpEx/ Lean Sensei: Support Plexus Aerospace & 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. Reduced Set-Up Time by 50%, Reduced No of Changeovers by 50% and Eliminated Redundant Process/Equipment. Updated / Modernized existing equipment. Standardized Kit Sizes and Scheduled Releases.

Sanmina-SCI – Huntsville, AL (Contract)

● OpEx / Lean Sensei: Support SCI Aerospace & 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 Future State to accommodate six continuous one-piece flow lines (3 SMT & 3 PTH) and 12 final assembly box-build/customer focused cells. Future State will reduce floor space requirements by 25% & lead time by 50%.

Electro Switch/Digitran – Rancho Cucamonga, CA (Contract)

● OpEx / Lean Sensei: 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% with In-line Testing & Real Time Feedback. Developed KPI for OEE, OTD, IT, FPTY and Build to Schedule.

AVCORP Composite Fabrication – Gardena, CA (Contract)

● OpEx / Lean Sensei: Support Lean Management System process improvement efforts for both the F-35 & 787 High Volume/High Mix Fiber Composite Fabrication value streams. Identify and Lead CI projects for the ATL, AFP, Gerber, Hand-Layup, Autoclave, Machining and NDT centers to meet customer recovery plan. Setup recovery teams based on cross functional support and kaizen bursts from current state value stream map to drive rapid improvements. Automatic Fiber Placement KPI was changed from lbs./hr to Inches/hr and programs revised 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 (Contract)

● OpEx / Lean Sensei: Support Lean Management System process improvement efforts for both the HDPE & PET resin High Volume/High Mix Multi Plant 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 Daily Team Maintenance plan based on Best In Class Standards and Plant Value Creation Analysis.

Parker Hannifin, Parker Aerospace CSD – Irvine, CA (Contract)

● OpEx / Lean Sensei: 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 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 (Contract)

● OpEx / Lean Sensei: Support Lean Management System process improvement efforts for both the Prime & Multi-Vision construction Low Volume/High Mix Narrow Web Flexographic Printing 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, Lean Conversion & 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 set-up time, make ready footage and MSI. Optimized Ink Mixing area with new layout. Restructured Kitting area based on Takt Time of Press requirements to One Piece Flow. Initial impact of $6M/yr, Future State in excess of $20M/yr.

Northrop Grumman Aerospace Corp. – El Segundo, CA (Contract)

● OpEx / Lean Sensei: Support Affordability process improvement efforts for both the F/A-18 & F-35 High Volume/High Mix Fiber Composite Fabrication value streams. Identified and lead projects for Kitting, Simple Skins, Complicated Skins, Ducts, ATP, Autoclave, Breakout, PMM & AUSS areas to meet customers recovery plan. Setup recovery teams based on cross functional support and kaizen bursts from current state value stream map to drive rapid improvements. 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 (Contract)

● Acting Director of Operations / Operational Excellence Leader: (Turn Around) Oversee core business and operational development functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) of Bankrupt factory. Set-Up Initial Lean Management System to support Med Volume/Med Mix Contract Electronic Manufacturing Value Streams. 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 on the Toyota Production System. Utilized Motorola Six Sigma Quality Control Techniques and Concepts to study & reduce variation in process. Re-established customer base and removed from Bankruptcy. Company Sold, $40M annually.

Boeing, IDS, SOF, Aerospace - Crestview, FL (Contract)

● OpEx / Lean Sensei: 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 (2000 to 2003)

● Operations Manager / Operational Excellence Leader: (Brown Field Factory Re-Organization) Oversee core business and operational development functions (e.g. P & L, Manufacturing, Materials, Quality Control, Engineering and Facilities) of $300M vertically integrated factory. Developed and Set-Up Initial Lean Management System to support Med Volume/Med Mix Contract Electronic, Wire & Cable, Plastic Injection Molding, Metal Stamping and Box-Build Manufacturing Value Streams. 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 on the Toyota Production System. Utilized Motorola Six Sigma Quality Control Techniques and Concepts to study & reduce variation in process.

Qualcon – Flowery Branch, GA (1996 to 2000)

● Manufacturing / Engineering Mgr. / Operational Excellence Leader: (Green Field Factory Start-Up) Developed initial factory layout based on One Piece Flow of Med Volume/Med Mix Contract Electronic Manufacturing Value Streams. Facilitate New Product Introduction, Map and Define Processes and Product Flow utilizing Process Control Manual. Teach, Mentor and Train Production Associates, Machine Operators, Technicians and Engineers on the Toyota Production System. Introduced Motorola Six Sigma 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 (1992 to 1996)

● Sr. Manufacturing Engineer / Operational Excellence Leader: (Green Field Factory Start-Up) Worked with team to develop initial Lean Management System utilizing Total Quality Management, Six Sigma and the Toyota Production System to established One Piece Flow of Low Volume/High Mix Contract Electronic Manufacturing Value Stream. Developed Floor Plan, prepared factory floor & ordered, installed & tested assembly equipment. Develop & Optimize assembly equipment programs, reflow oven and wave solder profiles to meet or exceed customer takt time. 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. Registration Received 09/95

AVEX Electronics – Huntsville, AL (1989 to 1992)

● Manufacturing Engineer / Lean Practitioner: Worked with team to develop initial Lean Management System utilizing Total Quality Management, Six Sigma and the Toyota Production System to established (10) One Piece Flow High Volume/Low Mix Contract Electronic Manufacturing Value Streams. Conduct Time Studies and record Process Cycle Times. Develop & Optimize SMT & PTH machine placement programs, reflow oven and wave solder profiles to meet or exceed customer takt time. Teach, Mentor and Train Machine Operators and Technicians. 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.

SCI – Huntsville, AL (1984 to 1989)

● Manufacturing Technician / Lean Practitioner: Conduct Time Studies and record Process Cycle Times. Develop & Optimize SMT & PTH machine placement programs, reflow oven and wave solder profiles to meet or exceed customer takt time Teach, Mentor and Train Machine Operators. Review machine operating efficiency reports, downtime data and 1st pass test yield to establish Overall Equipment Effectiveness metric. Study mean time between failures to develop predictive & preventative maintenance schedules on machines, feeders and peripheral equipment in support of Low Volume/High Mix Contract Electronic Manufacturing Value Streams.

● Machine Operator: 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.

Education & Credentials

BS Mfg. Eng. Tech. Jacksonville St. 1989

AS Electronics Shoals Community College 1987

HS Diploma Russellville High School 1984

References

Marion Zubrick SCI 256-***-**** 1 Yr Eng.

D.M. Jones Avcorp 310-***-**** 3 Yrs. GM

Justin Below Parker 210-***-**** 6 Yrs Lean

Eric Victor Parker 949-***-**** 6 Yrs Lean

Lazlo O. NGC 310-***-**** 10 Yrs Eng.

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