Robert (Bob) Foulks

***** ********* **.

Eustace, TX.

817-***-****

adir0h@r.postjobfree.com

QUALIFICATIONS PROFILE

Industrial Performance Engineer with 20+ years experience in hands on Manufacturing Engineering, Process Engineering, Equipment Engineering, Maintenance Management, Safety Planning and Project Engineering for multiple industries. Successful agent for change in multi production environments.

●Certified Six Sigma Black Belt. Coached Kaizen Team to 3rd place in worldwide competition event for Asahi Glass Corp.

●Proven record of starting C.I. programs from pre-development through post-development cycle. Increased operational profitability by enhancing processes.

* Inventor of three U.S. Patents and honored with the General Electric/RCA yearly Technical Excellence Award. Six Sigma programs, TPM, DMAIC, FMEA, RCA, RCM implementation and Kaizen (KTA) expert.

• Pioneered innovative process improvements for the fabrication of semiconductors, improving cycle time by 45% and reducing manufacturing costs by $550K in the first year. ISO 9001 site administrator.

• Led Six Sigma Lean programs to motivate employees to collaborate as top-producing teams concentrating on safety, productivity and cost reduction. • Implemented innovative process improvements using advanced SPC knowledge with Minitab to drive continuous process improvement across all manufacturing departments.

• Proven track record as a change agent, with strong ability to build versatile and cohesive teams to deliver business outcomes. Expert in implementation of TPM, SQDC, OEE, Poke-Yoke process and developing PM schedules.

• Formulated strategies to improve operational processes and practices, translating into operational plans.

* SAP Trained.

PROFESSIONAL EXPERIENCE

Biomerics FMI, Athens, TX. June 2019 - Present

Process Engineer with R/D Department

Developing all IQs, OQs, and PQs for new medical products introduction to manufacturing for stents, pushers, catheters and sheath/dilators.

Russell Stover Chocolate Inc. Corsicana, TX. June 2018 – May 2019

Lean Coordinator (Consultant) (Focused on Implementing Toyota Production System (TPS) using Lean Six Sigma Methodology). Created site 5S and PCS programs in three departments. These were the foundation programs for the pillar programs to create Training, PM management, Continuous Improvement and Self Directed Work Teams (TPM). Coached plant employees on use of Kaizen teams and Root Cause Analysis (RCA) for problem solving. Developed shared learning’s with other company plants. Achieved 25% improvement in efficiency which resulted in 12% cost reduction.

Americase LLC Waxahachie, TX Jan 2017-June 2018

Operation Excellence Manager (Focused on Continuous Improvement in Manufacturing)

Lead machine shop manufacturing teams to improve safety, job efficiency and employee utilization to close gaps in plant KPI metrics. To date all KPI metrics have exceeded 2017 goals by 15% and all goals have been raised to higher levels to encourage continuous improvement methods . Developed programs for Staff team and shops leads to introduce Lean Six-Sigma programs with RCA, 7-S and 4-DX.

Ventura Foods Saginaw, TX July 2016-Jan 2017

Maintenance Supervisor (Focused on Continuous Improvement for Equipment uptime and Process metrics)

Leading team of 8 technicians to develop focused improvements in Food Manufacturing and Packaging Production. Phase-2 completed using 5S, visual factory, SPC methodology and OEE statistics to measure quality improvements. All programs have been designed to close gaps in plant KPI metrics. To date all critical processes have achieved Cpk > 1.4 and equipment OEE has improved to >88% from original OEE < 51%. This equipment effectiveness reduce scrap by 32% and resulted in 14% cost reduction. Safety/Quality/Delivery/Cost area boards (SQDC) implemented.

Diodes Incorporated Lee’s Summit, MO. Jan 2015-May 2016

Department Director (Focused on Continuous Improvement for Equipment uptime and Process metrics)

Leading team of 12 technicians and 2 Process Engineers to develop focused improvements in Semiconductor production in Metals, Implant and Diffusion areas. Phase-2 completed using 5S, visual factory, SPC methodology and OEE statistics to measure quality improvements. All programs have been designed to close gaps in plant KPI metrics. To date all critical processes have achieved Cpk > 1.6 and equipment OEE has improved to >85% from original OEE < 45%. Safety/Quality/Delivery/Cost area boards (SQDC) implemented. These improvements resulted in over 900K cost reductions in the first year alone.

Graham Packaging Corp., Hammond, LA. July 2014-Dec 2014

Sr. Plant Engineer (Contract) (Focused on Six Sigma & Toyota Lean Improvements and team mentoring)

Developed 6 teams for Continuous Improvements on PET Blow Molding/Injection production lines. Additionally working with the Maintenance department to improve MOEE. To date MOEE has improved from 59% to 72% using 5-S process. The improvements made to date have resulted in a decrease in unscheduled downtime by 60%. Additionally, Mean-time-to-repair and mean-time-to-fail have shown a significant improvement that has resulted in the MOEE milestones. Currently have converted 6 of 8 productions lines to TPM concept that has allowed technicians to focus on equipment cross training and skills improvements. Developed close business relationship with Folgers’s Coffee (primary customer) to insure on time delivery and quality product. Reduced safety incidents by 20% by forming site safety team made up from all departments and implementing industry best practices

Asahi Glass Corp., Alvarado, TX.

2012 – 2014

C.I. Engineer & Maintenance Mgr. (Focused on Continuous Improvement at multiple AGC plants in Texas)

Used advanced principles of Lean Manufacturing and Six Sigma (2e-3e PDCA) to implement 5-S programs throughout the plant. Seven functional areas (Receiving Area, CNC Glass Cutting, Glass Tempering, Insulated Glass Assembly, Maintenance Dept., Supply Storage and Shipping) currently sustained and exceeding plant KPI goals. Additionally served as transportation manager for southwest region.

• Used time studies (Man vs. Machine) to understand POR and implemented changes that resulted in 30% improvement of overall plant output to meet customer satisfaction requirements. Reduced scrap by 15% month on month and decrease department downtime by 16%. Led the Maintenance dept. in equipment uptime improvement projects ( Cutting, Tempering, Fabrication and Insulated glass ). Overall savings in 2013 were $550K and $700K in 2014.

• Led programs to establish Safety and Quality as two tickets to success and established TPM to promote self-directed work teams in four manufacturing areas. Served as Plant Safety and Iso 9001 plant leader.

• Implement same CI programs at AGC glass fabrication facilities in San Antonio, TX and Houston, TX.

Honeywell International, Richardson, TX

2005 - 2012

Manufacturing Engineer Level 4

Led cross-functional team of 22 personnel in corporate process engineering and manufacturing engineering for multi-plant operation. Manage product development, product specifications and drawings, project management, cost analysis, plant maintenance engineering, and process troubleshooting. Process expert in Diffusion, Plasma CVD and Ion Implant.

• Reduced costs $550,000 per year, implementing initiatives to reclaim process quality monitors from vendor facilities to Richardson and Golden Valley manufacturing facilities.

• Guided product innovation across multiple engineering divisions, contributing to performance and productivity gains.

• Drove business improvements, ensuring commercial and best practice objectives were met.

National Semiconductor, Arlington, TX

1992 - 2004

Plant Engineering Manager, Production Area Manager, Equipment Manager

Managed and directed manufacturing operations, production control, process engineering, quality control, budgeting, tool selection process, cost reduction, administration, inventory control, and troubleshooting. Responsibility for three sub micron fabrication areas. • Implemented TPM and RCM across all three manufacturing areas.

• Coordinated new product introduction without interruption to production and customer requirements.

Prior Semiconductor Experience- General Electric / RCA and MOS Technology ( Commodore Semiconductor )

Military- Served 8 years in USAF- Achieved E-6 rank as an Electronics Crypto Systems Technician.

EDUCATION

BBA, University of Maryland College

Chemical Engineering, Lehigh University

Training:

Graduate General Electric Management Program

Management Training Texas Tech University

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