ALI FOUANI, NPDP (Willing to Relocate)

Whatsup - Cell 313-***-**** - adjfnb@r.postjobfree.com

Interviewed by Genna Weiss from Six Sigma IQ (Podcast: DFSS tools you need to know right now)

http://www.blogtalkradio.com/six-sigma-iq/2009/12/02/design-for-six-sigma-tools-you-need-to-know-right-now

CAREER PROFILE

Seeking a leadership position in a competitive and innovative organization that provides responsibility and professional growth.

Senior research and development engineering executive with strong skills in medical and automotive global operations. Outstanding abilities to solve issues quickly and effectively. Expertise in conceptualization, design thinking, product launches and support. Design for Six Sigma Master Black Belt. Team leading, coaching, training, analyzing complex data, process improvement, utilization of Bridgewater Principles to solve problems, product enhancement and re-design. Ability to focus on the execution of daily requirements, as well as looking ahead.

AREAS OF EXPERTISE

VOC, VOP, QFD, Pugh Concept Selection, Integration of Benchmarking, Product Development and Launch, Design for Manufacturing & Assembly, Systems Thinking, System Engineering, Design Thinking/User Experience, Innovation, TRIZ, Lean Design, Lean Manufacturing, Six Sigma, Toyota Production System, A3 Process, Operational Excellence, Design for Six Sigma, Design of Experiment, Reliability, Engineering Management, Product and Process Improvements, Product and Process Characterization, Process Validation (IQ, OQ, &PQ), Risk Management, Design Control, Best Practices, Bridgewater Principles, Process Validation, Process Optimization, Lessons Learned, Critical Thinking, Quality Management System, CAPA, and Problem Solving.

PROFESSIONAL EXPERIENCE

ZOLL MEDICAL/CARDIAC SCIENCE, DEERFIELD WI

Principal Supplier Quality Engineering/Quality Engineering Director 2018-Present

Responsible for ensuring new product development adhere to best practices, in addition responsible for quality in manufacturing and dealing with suppliers to improve products and processes.

Travelled to Thailand to witness first PCBAs builds at our contract manufacturer and to address any concerns on the spot.

Travelled to China, Malaysia, Philippines, and Thailand to audit, improve processes, and prevent defects from being produced.

Coached and mentored Contract Manufacturers to develop robust processes and utilize optimization DOE in Process Validation.

INDEPENDENT CONSULTING / CI & Operational Excellence 2015-2018

American Medical Systems (Endo Pharmaceutical) / Boston Scientific / Cardiac Science / Others

- Products: Pelvic Implants: Hydraulic Urinary Sphincter & Penile Prosthesis (Implantable devices)

Coaching and mentoring team members in CAPA investigations, problem resolution, data analysis, product and process characterization, design of experiments, measurement systems, and developing of Engineers.

Drafted and executed a strategy to characterize a new machine to replace a current line for “InhibiZone (IZ) Antimicrobial Treatment Process Validation”

Resolved concerns in manufacturing yield of Kink Resistant Tubing (KRT) which resulted in an annual saving of an estimate of $1.4 M.

Interacted with executive leadership regarding specifics of strategy, direction, execution, recommendations, and advised on key individuals for development and competency.

Statistical Analysis for FDA Remediation (Analysis of historical data, DOE’s, Process Characterization & Optimization, and Monte Carlo Simulation) – Saved the company more than $2 M as a result of analyses vs. actual testing.

Suggested improvements based on Human Factors study and benchmarking to refine, revise and change the design to make it more user-friendly.

Privately held company (Medical Devices) - CA

- Products: Surgical Products

Developed risk management training for production and trained about 165 engineers in the methodology of PFMEA and the importance of Control Plans.

Coached and mentored 4-5 Engineers “Train the Trainer”, so they can become self-independent and competent in teaching and coaching PFMEA’s.

BRIDGEWATER ASSOCIATES, Westport, CT

Process & Metrics Excellence Manager 2014-2015

Advised on new facilities metrics to drive process excellence and continual improvement within QMS.

Managed day-to-day activity for business process management and responsible for Kaizen activities.

Reviewed, audited and approved process maps for publication, instrumental in running repeatable processes.

BAXTER HEALTHCARE, Round Lake, IL and Medina, NY

Technical Director / Design for Six Sigma Master Black Belt 2007-2014

Managed group of engineers responsible for failure investigations, and CAPA's, which increased problem resolutions, improved turn around yield, and increased competency level within the engineering department.

Interfaced with FDA during audits, presented status of CAPA's that resulted in great feedbacks from FDA.

Collaborated and consulted with functional leaders, including engineering management, risk analysis, design control, product development, and manufacturing issues.

Reviewed and audited key programs, business processes in accordance with FDA guidelines and regulations.

Planned and developed multiple MSA’s and DOEs in product/process design, increased product performance.

Coached and mentored Packaging and Manufacturing Engineers in Singapore on methods to optimize form-fill-seal operating parameters for sterile package, which increased efficiency and improved performance.

Planned and executed multiple sessions in QFD, Pugh concept selection, DFMEA, PFMEA Control Plans, brainstorming, strategic initiatives for practical sense from challenging data analysis, and performed multi-objective optimization analysis to streamline product design methods.

Managed group of engineers responsible for tear down analysis, failure investigations and CAPA’s, resulting in identification and resolution of major problems for customers and FDA submission.

Submitted paper to iSixSigma Conference, with recognition as Innovative Project utilizing DFSS/Lean methods.

Partnered with Manufacturing to improve internal competencies, using PFMEAs and Control Plans.

Designed screening DOE (Placket Burman) with resolution III that improved quality (The big Y = Silver Coating), reduced scrap, characterized process, resulting in $490K savings per year. (Costa Rica)

Designed and analyzed DOE for disposal pumps with 4 outputs. Extracted transfer functions, recommended proposed settings for inputs, and simulated model via Monte Carlo.

Coached and mentored material team on non-PVC tubing development effort by utilizing Lean/DFSS tools, resulting in increased performance, increased productivity and cost saving of $450K plus.

Developed Design for Six Sigma Overview Training with collaboration with Business Excellence.

Created company’s DFSS training material (QFD, Pugh Analysis, TRIZ, MSA, Regression, DOE, DFMEA, PFMEA and Control Plans).

Partnered with team leaders to provide coaching and guidance, and recommended DFSS tool usage.

Recommended corrective actions and Poke Yoke Fixtures to Singapore’s and Buffalo Grove Service operations.

Recommended process parameters for injection site packaging (process characterization), which improved seal strength.

Traveled to Baxter’s Singapore: developed strategies for design transfer and process validation. Applied Lean Thinking to improve process and reduce defects from 44 to zero.

Coached and mentored Green Belts and Engineers in methods of Six Sigma and Lean Thinking.

LEAR CORPORATION, Southfield, MI

Design for Six Sigma Master Black Belt 2001-2007

Interacted with executive steering committee for product enhancements and process improvements.

Selected as key team player to support internal/external customers, developing multiple DOE strategies in product development and solving manufacturing variations to improve design process.

Extracted multiple transfer functions and used simulation (Crystal Ball) to improve design/process.

Created Quality Control procedures and set benchmarks for quality goals achievement.

Masterminded FMEA audits that significantly improved product and depth of knowledge and expertise.

Integrated FEA and DOE, which led to time reduction in product development and improved performance (Outputs modeled “Frequency –BSR”).

Developed plan to include DOE’s and RED-X techniques to solve for component/build variation with Tier II supplier for one system. Presented findings to supplier and recommended corrective actions. Integrated Six Sigma, DFSS, and Red X in studies.

Recommended studies and experimentation to improve headrest effort and rattle, resulting in increased performance and efficiency across multiple plants.

Developed multiple DFSS courses and conducted DFSS training for 1,100+ engineers.

Visited multiple plants/suppliers for quality concerns, recommending strategies and action plans to resolve issues.

Reviewed Black Belts projects from plants and suppliers, recommending corrective action plans.

Established quality measurements, suggested 30 ideas to improve product/process, throughput and productivity in Mexico plant; Designed several POKA-YOKE fixtures; Redesigned GMX-295 End Frame line, which increased outputs of parts from 245/day to 320/day, and improved quality.

Conducted data analysis, DOE; applied Lean Tools/philosophy, DFSS, and manufacturing expertise to assist supplier with shipping parts and prevent closure/s of plants, resulted in savings of $300K.

Trained, and mentored by Shin Taguchi in two critical projects for General Motors. Published paper with GM; Title: Understanding customer’s feedback with respect to Backset (FMVSS 202a) and head-restraint comfort.

Coached engineers in use of Concept FMEA to aid in developing safety systems. Reviewed and audited multiple programs in usage of FMEA.

Developed Design for Lean (Design for Manufacturing and Assembly) module for teaching DFSS module.

Trained directors, managers and engineers in Design for Six Sigma methodologies/Systems Engineering. Classes taught: Introduction to DFSS, QFD, VOC, TRIZ and Design Trade-offs, Basic Statistics, Reliability, Design for Lean, DFMEA, Regression and DOE, Product Design and Variation, and Design Optimization.

Mentored DFSS teams through initial start-up of DFSS implementation, increasing productivity.

Black Belt (DMAIC) 1998-2001

Worked on Six Sigma project, dealing with GM Service operations, which enhanced drawing release for GM.

Worked with maintenance department at Auburn Hill plant to reduce maintenance inventory, control of material, and standardize process, which projected cost savings of $450K.

Prior to 1998

DELPHI AUTOMOTIVE, Warren, MI Prior to 1998

Sr. Product Engineer

Implemented cost saving ideas and continuous product improvement, resulting in saving of $300K.

Traveled to Lear Italy to assist on startup of launch for Fiat Multipla. Transferred all design responsibilities from Lear USA to Lear Nottingham.

Identified rattle noise cause in Fiat Multipla and H-Car programs; recommended corrective action and solutions.

Redesigned front stops (major design adjuster changes “safety concern”) for Fiat Multipla program, reduced travel per customer design, resulting in improving customer relationship and reliability.

Friendship Industries Inc., Sterling Heights, MI, Project Engineer

Gonzalez Design Engineering, Warren, MI, Specifications/Product Validation Engineer

EDUCATION

Columbia Business School - Certificate Course -Systematic Invention Thinking - Completed: December 2017

Massachusetts Institute of Technology – Sloan School of Management - Completed: October 25, 2017

-Innovation of Products and Services: MIT’s Approach to Deign Thinking; Certification Course, 2017

Master of Product Design and Development, Northwestern University, Evanston, IL, 2013

Master of Engineering in Manufacturing Systems, Lawrence Technological University, Southfield, MI, 2003

- Completed Coursework related to Doctorate Program in Manufacturing Systems at LTU

Bachelor of Science in Mechanical Engineering, University of Michigan, Dearborn, MI, 1994

ADDITIONAL TRAINING

TRIZ (Theory of Inventive Problem Solving); General Electric, 2011

Certified in Configuration Management “CMII”; Institute of Configuration Management; Phoenix AZ, 2010

Response Surface Methodology using EcHip; Baxter Training, 2010

Design for Reliability; Baxter Training, 2008

DRBFM (Design Review based on Failure Mode) Training, Toyota Motor Company, 2007

Lean Training (Lear Corporation), 2007

Attended Design for Six Sigma (DFSS) Training, Chrysler (one week) by Shin Taguchi, 2007

Attended DFSS Training, General Motors Corporation (3 Weeks). Training -by ASI (Shin Taguchi), 2006

Red X (Shainin Techniques), General Motors University, 2003

Design for Six Sigma Master Black Belt Certification thru Lear Corporation, 2003

Leadership Training, Crystal Clear Concepts, 2003

Design for Six Sigma Training, Statistical Design Institute, 2001

Successfully completed the following of Lear Internal Training Program/University of Michigan (3.6 CEU’s Awarded): Human Factors and Ergonomics, Materials and Recycling, Vehicle Electronics Occupant Safety, Noise Vibration and Harshness / Acoustics, Vehicle Packaging, Automotive Interior Systems. 1999

AFFILIATIONS

The Society of Manufacturing Engineers, and Product Development and Management Association

CERTIFICATIONS

Certified NPDP (New Product Development Professional –PDMA); Certified Lean Design Innovation Professional – Huthwaite Innovation Institute; Certified in Configuration Management “CMII”;Design for Six Sigma Master Black Belt Certification thru Lear Corporation, 2003

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