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Sr. Director of Manufacturing Operations

Location:
Des Plaines, IL
Posted:
January 16, 2020

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Resume:

VIKAS R. PATEL

**** ******** ****. *** *******, Illinois 60016

224-***-****

adbbqa@r.postjobfree.com

SUMMARY AND PROFILE

Six Sigma Black Belt certified with over 20 years of impressive Operations, Manufacturing, Logistics, Supply chain, Quality, Safety, Responsible Recycling (R2) & Project Management professional with demonstrated record of increasing responsibility and authority. Extensive background in new product introduction, customer on-boarding, planning, international plant transfers, change management, start-Ups, international & domestic multi plant operations and customer service.

A result oriented business professional with proven abilities to improving operational performance, problem solving, decision-making, team building, quality, productivity and profitability. Achieving results and cost control through motivating others and by most effective use of man power & available resources. Multi-plant operations experience in U.S, China, Europe and Mexico.

Professional Accomplishments:

Result Driven Visionary with Great Communication & Leadership skills:

Achieved $6.2 million savings in productivity and cost by streamlining process, process improvement utilizing Lean Six Sigma, process automation & project management methodology.

Achieved $1.25 million savings in warranty & customer returns through business process improvements.

Achieved $1.2 million savings & 35% quality improvement through identifying and eliminating waste and improving manufacturing processes. (DMAIC & Lean Methodology)

Successfully managed “Differential Supply Chain” project, which resulted in net inventory reduction of $3 million

Increased on time shipment by 30% and improved customer satisfaction by, improving follow-up and increasing coordination between customer service department, manufacturing and shipping.

Achieved 40% operational efficiency, 60% storage capacity, 66% TAT improvement and 15% floor space (21,000 Sq. Ft.) by modifying floor layout, automation & process redesign.

Improved quality by 30% & labor cost through product design improvement & manufacturing process improvement.

Successfully introduced 64 products in 4 months & achieved full capacity plant operation in 6 months through teamwork & project management leadership.

Successfully restructured organizations & operations to address business growth, cost reduction & service improvement while adding $1 million to the companies’ SG&A.

Successfully led cross functional teams across Business units and facilities for various projects, managing conflicts, delivering results, including communication to the management team.

PROFESSIONAL EXPERIENCE

Focal Point Lights, Chicago, Illinois

Senior Director of Manufacturing Operations

Feb. 2019 to Sep. 2019

Responsible for entire Manufacturing Operations & Operational Excellence (Fabrication, Assembly, Paint, Manufacturing Engineering, Industrial Engineering, Facilities, Safety, EHS, Quality, Warehouse & Shipping Operations, Purchasing, Planning)

Identified ~$2M cost savings opportunities and realized savings of $300K within 8 weeks.

Identified Make vs. Buy strategy.

Responsible for 2 shifts & 700 employees.

Brightstar Corporation, Libertyville, Illinois

Director of Operations & Operational Excellence

May 2015 to Feb. 2019

Successfully resolved employment turn-over by 80% through creating incentive and training programs

Implemented & maintained ISO 9001, 18001, 14001 & R2 programs and certifications.

Completely rebuilt a dysfunctional management team in high volume logistic & production operations environment.

Reduced Quality control staffs by 40% by implementing realistic yet reach out quality goals utilizing statistical tools, benchmarking & adequate sample size plan for inspection resulting in $800K in cost reduction.

Developed and Implemented Lean Six Sigma Program.

Managed over 1500 plus employees in a non-unionized environment.

Developed and Implemented robust safety & Quality assurance program.

Implemented meaningful measurement metrics for safety, quality, on time shipment & TAT

Implemented Labor management system to manage labor productivity, time and attendance for floor operations.

Full P&L and budget responsibilities of $250 million annually

Brightstar Corporation, Libertyville, Illinois

Sr. Manager Operations & Operations Excellence

May 2013 to Apr. 2015

Successfully creating and implementing strategic plans, reach out goals, budgets and developed improved process to meet short and long term objectives, resulting in CPU improvement of 75%.

Over show facility operations to ensure facility requirements are met within budget and design plans for improvements to meet goals & customer satisfaction.

Developed & implemented automated process by working with third party vendor/partners (Identifying and approving new third party vendors/partners, performing POC etc.) resulting in elimination of manual processes,

Increased out-put by 200%, equipment reduction of 90%, overhead reduction of 50% & improved first passed yield by 50%.

Developed quality & exceptions database, Capacity planning tool & operational reporting for visibility and better decision making.

Owner KPI & PKI Corp. (Consulting)

June 2009 to June 2016

Successfully revamped operations of new restaurants by increasing weekly sales by 13%; reduced inventory by 40% and payroll by 24%. (Market study, advertisement, local promotions & process optimization)

Spearheaded the grand opening from ground up of two profitable restaurants and takeover of 3 existing restaurant.

Developed and implemented standardized and consolidated processes for 14 distribution centers resulting in savings of $500,000.

Philips Lighting Electronics N.A., Rosemont, Illinois

Six Sigma Black Belt – Business Excellence - (Sr. Manager Global Business Excellence operations)

June 2005 to Sep. 2009

Responsibility included breakthrough process improvement via DMAIC & Lean methodology, working on Black Belt projects, coaching Green Belt candidates, provide Green Belt training, identifying Black Belt, Green Belt & process improvement projects that align to the top level business objectives.

Developed and introduced RoHS process for global operations, to deliver and meet the RoHS compliance product requirement from the customers.

Developed global teams (test engineering, operations equipment & sourcing) to standardized processes across global operations.

Managed and directed cross-functional teams to efficiently achieve lean manufacturing, improve performance, quality and cost objectives for new product introductions, product sourcing and manufacturing solutions.

Developed product transfer plan and successfully manage the transfer of unique products from China to Mexico, resulting in satisfying seasonal spikes in customer orders & revenue.

Circuit Service Inc., Wheeling, Illinois

Plant Manager Manufacturing

May 2004 to May 2005

Responsibility included process improvement & implementing process changes.

Optimize “receiving” process by 25% & Reduced “Put Away” time in stockroom by 100%.

P & L responsibilities for $30 million/year operations.

Implementing Lean Manufacturing practices.

Cut OSHA Recordable accidents by 66%.

Lila Construction Inc., Des Plaines, Illinois

Operations Director

July 2003 to Apr.2004

Responsibility included managing office staff, daily plans, collections, scheduling, site-visits & completing the tasks on time to meet the delivery schedule.

Energy Savings Inc. / Universal Lighting Technology

Manufacturing and Transition Director

Oct. 2002- July 2003

Responsibility included integration of products and product lines as part of acquisition of Energy Savings Inc. by Universal Lighting Technology, and assisting the Plant Manager in overseeing operations for 1800 employee plant in Mexico.

Energy Savings Inc. / Universal Lighting Technology

Manufacturing Director

July 1999- Oct.2002

Responsibility included managing manufacturing plants in U.S. and Mexico.

Improved machine up-time by 40%, resulting increase in plant output increase.

Achieved two years of accident free operations by putting emphasis on training and safe procedures for conducting work and operating machinery.

P & L responsibilities for $20 million/year operations

Implemented racking system with designated bin locations, improving inventory utilization and reduced line down time by 20%.

Managed customer service organization, shipping and warehouse personnel during company’s difficulties with cash flow and lack of raw materials for manufacturing prior to and after filing for bankruptcy.

Energy Savings Inc. / Universal Lighting Technology

Productions Supervisor

June 1997- June1999

Responsibility included managing manufacturing plant in U.S. [Responsible for Budget of $1.2 million, 2 shifts, 2 direct reports, and 60 hourly employees, including scheduling, machine maintenance, performance appraisals, staffing issues, time card verification and meeting production and quality goals].

EDUCATION

Nagpur University - India

Bachelor of Science in Electrical & Electronics Engineering

Six Sigma Black Belt Certified (Philips Electronics N.A.)

Design for Six Sigma Trained (Philips Electronics N.A.)

Quality Improvement Competition Judge (Philips Medical - Aurora, IL)

IL State DECA Judge for two years 2012 & 2013 (Decatur, IL)

Won Oscar award for Innovation at Brightstar Corporation 2013 & 2015 (Libertyville, IL)

OSHA 10 General Industry Safety and Health Certification

Health, Food safety & Sanitations license and certification



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