Robert J. McFalls

Twin Lake, MI *****

231-***-****

adgkfd@r.postjobfree.com

linkedin.com/in/robert-mcfalls-9662805b/

PROJECT MANAGER LEAN SIX SIGMA PROFESSIONAL

Driven engineering leader with an extensive background that includes aerospace, defense, automotive and hydroelectric engagement. Project Management experience includes component manufacturing, engineering design, system development, manufacturing support and quality planning. Proven self-starter and leader through dedication, commitment, and integrity. Methodology used for problem solving and further learning relies upon Lean/Six Sigma tools and DMAIC implementation. Skills Include:

Team Development & Motivation

Continuous Improvement Initiatives and Training

Lean/Six Sigma Black Belt

Cost Justifications

Effective Communicator

Proficient in Microsoft Office

Coaching/Mentoring/Formal Training

Mechanical Engineering

Quality Initiatives & Maintaining Standards

Project Scheduling

EXPERIENCE

GE Aviation, Muskegon, MI June 1999 – July 2020

Sr. Black Belt/ Cost-Out Focal (Core Staff), Jan 2017- July 2020

Re-engaged the Lean Six Sigma Program within GE Aviation Muskegon, as well as managed the Cost-Out Initiatives required to stay competitive and maintain productivity.

Cost-Out Focal managed between $14MM-$24M Annual Cost Savings with over 400 projects in the pipeline at any given time.

Received GE Black Belt Certification & advanced Minitab 19 Accreditation

Lean Six Sigma activities included: 7-Ways, 3P, 5S, AWO’s, standard work development & implementation, root cause analysis, SPC and corrective action efforts

Trained over 100 associates from cross disciplines in GE Green, Yellow & White Belt Certification in 16 months.

Participated in LEAN/ Six Sigma site evaluations for other GE sites: OMR South Ohio Tour

Technical Resources Director (Core Staff), June 1999 – Jan 2017

Responsible to develop and manage Manufacturing and Quality Engineers, Metallurgists, Met Lab, Metrology, Tool Room & Design Departments

Led growth from 34 to 123 direct/indirect reports

Growth & Engineering development of over 22 flow lines, introducing automation efforts and specialized machine development. Includes Apollo Root Cause and SPC monitoring

Developed growth through the expansion from one building to 3 plants (85,000 ft2 to 220,000 ft2)

Output growth from $100M to approx. $400M in annual sales

Extensive Manufacturing experience in EDM, CBN grinding, conventional machining, vacuum furnace brazing, laser drilling, airflow & various inspection techniques.

Sustained Quality System improvements, process certifications (NADCAP), customer specs and internal standards/work instructions. Sustained World Class loss reductions.

Completed various GE Learning Classes: Diversity, Integrity, Import/Export Regulations, GD&T, Specification Review Committee, Cooled Nozzle Commodity Team & Airfoil Commodity Team Member.

Facilities Manager, June 1999 – June 2000

Transformed the Maintenance Departments in two (2) different locations to improve shop support and machine up-time. Established proficiency and performance tracking.

PRIOR WORK EXPERIENCE

CMI International, INC., Montague, MI

Automotive Project Manager - Led the development and integration of new product lines. Worked with various cross-team members to design, test and manufacture new automotive components. Tier One supplier for top 3 automotive manufacturers and international companies. Developed and Maintained PPAP manuals for New Product Development to Ford for three (3) safety critical components.

Voith Hydro, Inc., York, PA

Business Development Manager - Developed and managed proposals & quotes for support hydro development or reconstruction project with the private sector, foreign development and the U.S. Army Corps. Of Engineers.

Sr. Application Engineer/Project Manager - Managed hydroelectric projects, domestic and international. Initiated proposals and site evaluations for new and existing hydroelectric developments.

TRW/Chromalloy American Corporation, Harrisburg, PA

Product/Process Engineer - Responsible for the engineering development of new products (HPT nozzles and blades) to Pratt Whitney and General Electric. Responsible for manufacturing support, tooling and process development. Chromalloy purchased TRW in Aug 1987.

EDUCATION

The Pennsylvania State University

BS in Mechanical Design Engineering Technology – Complete

University of Phoenix

MBA Classes – Two (2) Semesters Completed

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