Manager Lean Six

Terry O’Brien

Tacoma, WA ***** • 253-***-****

**************@*****.*** • linkedin.com/in/Terry O’Brien

Summary

Motivated Production Manager with 16 years of experience in supervisory, leadership, and coaching roles. My specialties with Lean Manufacturing and Kaizen techniques will help guide your organization to achieve goals, drive revenue, and ensure operational efficiency. My strength is the ability to drive change while simultaneously building Operator ownership and involvement.

Highlights

-Proficient in Kaizen, Kanban, and 6S; held three Kaizen events resulting in 22% production increase

-AS9100 experience; Zero major or minor discrepancies in 2020 audit

-Chairman of the Continuous Improvement Process and Corrective Action Teams

-HACCP experience creating control points for mint, personnel care product, and aerospace manufacturing

-Increase on-time-delivery from 72% to 100% while decreasing overtime from 8% to 5%.

-Currently enrolled in the Lean Six Sigma Black Belt Certification Program through Villanova University

-Microsoft Excel, Microsoft Work, and PowerPoint proficient

-Excel in time management and creative thinking

Professional Experience

Sekisui Aerospace, Auburn WA

Production Manager 01/2020-Present

Developed policies and procedures for production, quality, and shipping of composite ducting supplied to Boeing, Spirit, GKN Aerospace, and Kawasaki Aerospace. Responsible for tracking and accountability of Quality Control and KPIs over continuously moving lines in the Lamination, Trim, and Assembly departments to ensure 100% AS9100 compliancy. Directly managed seven Supervisors, three Trainers, and four Production Control personnel over two shifts to provide direction, maintain budget, and coordinate production for 330+ personnel. Analyzed customer demand through Epicor ERP system to develop a scheduled work flow that exceeded customer need dates.

-Lead Japanese and domestic Kaizen team in two Kaizen events leading to a 22% production increase

-Brought the company from being 1100+ parts behind schedule to a full 20-day supply in stock; turning a 12% loss each month to a 5% profit (a swing of approx. 2.5m annually)

-Increased on-time-delivery from 72% to 100% for 68 consecutive days

-Created “TOP 5” program, resulting in a decrease of 58% scrap - saving $500,000 annually

-Increased First Pass Yield quality by 7% - highest 1-month average seen in the company in four years

-Through continuous improvement development teams, created simple Freekot coating process improvement that resulted in a material savings of $50,000 per year

-Evaluated and improved safety protocols resulting in reducing recordable injuries 200%

-Drove Business 4.0 teams to technology visions reducing shipping time almost in half

-Assisted Engineering in creating an insulation cutting process

-Reduced personnel from two to one allowing focus on composite part prep work

-Reduced daily total time needed from 900 minutes to 60 minutes.

Formula Corp, Auburn WA

Plant Supervisor 02/2018-12/2019

Hands-on Supervisor that managed day-to-day plant management of six production lines to ensure FDA and OSHA regulation compliancy. Supervised three Leads and 48 employees over Blending, Production, Maintenance, and Warehouse work centers to accommodate operations in accordance with customer needs and stock requirements for over 40 customers worldwide.

-Process Improvement Lead – Improved bottle production from 48 to 71 bottles per minute. This led to the acquisition of Target, Super Value, and Thrive companies culminating in the first month of $4 million revenue and over $42 million annually

-Corrective Action Preventative Action (CAPA) board member – through Process Change Control, lowered the weekly average open CAPAs from 13 to 6

-Implemented 6S plant-wide enabling a 10% decrease in cycle times increasing productivity 33%

-Wrote and implemented 32 SOPs. Created the company’s first Operator Training Plan Trained over 60 employees to cover operations, safety, and proficiency

Callisons Inc., Lacey WA

Production Supervisor 01/2015 – 12/2017

Direct supervisor to three leads and 18 personnel staff. Responsible for management and company production fulfillment duties. This includes process improvements, budgets, quality control, safety, and enforcing company policies.

-Developed and executed procedures that secured a $2.2 million annual contract

-Identified and corrected out of compliance protocols that earned the company’s first AA rating through the British Retail Consortium (BRC)

-Increased production by 2.3% within six months by redesigning workflow between every department

-Assisted in Labor Union and Contract Negotiation

-Performed analysis on testing material to ensure 100% customer compliance

Corix Corp, Kirkland WA

Regional Field Supervisor 02/2009 – 12/2014

Self-starting Manager with a flexible schedule that lead two supervisors and three leads as the Regional Supervisor for the Northwest Territory. Created and executed strategy to implement a Mobile Reader database which nearly doubled production numbers (1.3 million meters read to 3 million meters read)

Education / Certificates

-Master’s Degree Business Management / St Martins U (in process)

-Bachelor’s Degree Business Management / St Martins U

Graduated Summa Cum Laude

-Lean Six Sigma Greenbelt Certification / Villanova University (in process, complete 2/21)

Military

-United States Navy (1993 – 1995)

-United States Air Force (1999 – 2007)

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