GREGORY C. MONTEMURRO

Westford, MA ***** LinkedIn.com/in/GregMontemurro 978-***-**** adtxxp@r.postjobfree.com

PLANT QUALITY MANAGER

Executive combining highly effective quality and engineering leadership across the product life cycle and supply chain resolving critical quality, safety, manufacturing, and environmental concerns utilizing a holistic systematic approach. Adept at building large cross functional teams with a guiding vision and mission focused on delivering critical business results. Significant experience in developing quality operating systems in multi-plant situations by integrating key performance indicators and lean systems uniting engineering and manufacturing teams. Offer extensive international experience; Europe, China, Japan, Mexico, and Southeast Asia, including five years of international service with Ford Motor Company in Germany and Japan.

SKILLS

Product Development Product Management Product Innovation Quality Operations Six Sigma TPM TRIZ DFSS Lean Production Planning Strategic Planning High Performance Teams Consumer Products Engine Design PPAP Injection Molding Thermoforming Process Engineering Mechanical Engineering Design of Experiments Procurement Site Sourcing Hoshin Shingo HACCP ISO 9001 Statistical Modeling QMS/CAPA Root Cause Analysis Supply Chain Management & Optimization

Symbotic LLC, Wilmington, MA 2020 - Present

Head of Quality

Responsible for overall product quality for robotics, automated industrial equipment, and site quality across ten customer sites and two production centers in Wilmington, MA and Montreal, Canada.

Developed a Quality Operating System based on principles from ISO 9001:2015 which standardized quality workflows enabling high volume production at all customer, supplier, and manufacturing sites.

Created an internal analytics teams using SQL/JMP databased enabling serialization of product driving daily reports of key quality metrics, KPIs for vendors, sites, and customer dashboards.

Identified CTQs, used cascading checklists based on engineering instructions and drove bot quality levels to 98% acceptance out of box, site right first time to 94%, and improved fleet reliability at three months in service from 64% to 89%.

Built relationships with engineering while applying DFX concepts enabling field replacement of all critical sub-systems in less than 30 minutes.

Keurig Dr Pepper, Burlington, MA 2011 - 2020

Senior Director Operation Development & Engineering – October 2018 to October 2020

Oversee overall execution and delivery of manufacturing and equipment engineering across six plants for the product commercialization of the recyclable K-Cup.

Served as architect of the equipment upgrade which touched all aspects of the Keurig operations across 95 production lines and enabled the delivery of $ 60 M annually in productivity.

Created engineering standards and playbooks for operators, engineers, maintenance techs, and leadership improving product quality and line performance metrics.

Develop a tiered approach for commissioning and qualification for first of a kind lines through standard operations which enabled all line conversion to proceed ahead of schedule and under budget.

Co-ordinated with original equipment manufacturers and resolved technical obstacles while creating a set of executive dashboards enabling quick resolution of issues and alignment of the entire team.

Directed cross functional teams focused on underperforming production sites and increased OEE from 40% to 70% by focus on clear SOP combined with TPM and A3 thinking which sustained gains.

Collaborating with EH&S teams created heat map models and a detailed statistical database which expedited organizational learning enabling improved traceability and identification of segmentation plans.

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Senior Director Packaging & Process Quality Engineering – May 2015 to October 2018

Responsible for overall launch quality, primary package system, performance, equipment integration, and characterization across Keurig.

Directed packaging product strategy and creation of a pod packing product roadmap resulting in over $35 million in productivity improvement in 2018 FY.

Created standardized recipe controls (time, temp. pressure) coupled with a quality master validation model enabling early detection of non-conformance resulting in significant reduction in customer and partner complaints.

Ensured Keurig and supplier labs capability exceeded 1.33 Ppk and achieved correlation between all labs to a precision of less than three microns through standardization of procedures and SOPs

Led a high performing tiger team in resolution of the Flint Ink adhesion concern using data and structured problem solving resulting in root cause resolution confirmed in labs, supplier sites, pilot plants, and Keurig’s factories in less than five weeks.

Developed quality control plan for all suppliers focused on upfront automated data collection providing detailed analysis of cup performance during launch +90 days enabling a long-term control plan based on technical maturity of product and process.

Resolved thin wall injection molded cup launch concerns by collaboratively working with supplier to implement an operating system focused on reducing downtime, creation of a clear quality library, and standardization of KPIs resulting in exceeding the demand plan of Montreal Plant and securing the Canadian launch and commercial conversion to the Polypropylene recyclable K-Cup.

Technical leader of concurrent engineering team driving the launch of the recyclable K-Cup (Injection Molded and Thermoformed Polypropylene, 1.0 B cups, 3 plants in FY18)

Lead technical integrator with Coca-Cola and resolved cold pod system launch concerns (lid, valve, pod, welders, seals, equipment) delivering a product/process capable of a Ppk = 1.33 for Polypropylene and Polyethylene Terephthalate pods.

Led HACCP audit of Bevyz’s plant in Kirchhasel Germany resolving critical food safety concerns and improved packing machining throughput.

Worked with the Keurig manufacturing network and created a multi-generational plan, green bean thru secondary packaging, delivering $26 M in annual savings.

Senior Director Manufacturing Operations – December 2012 to May 2015

Responsible for delivery of new products, creation of world class launch processes, driving ongoing contract manufacturing, optimization of ongoing production, capital assets, and quality improvements across OEMs and critical sub-tiers in the value chain.(Seven Sites in Asia)

Built and transformed a manufacturing team, in the US and China, using PPAP, systems engineering, and lean thinking into a team which consistently delivered high volume launches with no rework.

Retooled twenty production lines, brought 1000 injection mold sets online, and created a manufacturing quality system, while launching 4 M appliances across four factories in four months exceeding all launch objectives.

Transformed manufacturing approach across five CMs and synthesized lean with inline analytics creating intelligent lines enabling transparency and traceability from China operations to Keurig headquarters in Boston.

Worked with IT and CM quality leadership, developed an automated quality system enabling data, lot code, birth history, and non-conformance tracking reducing response time and supply line inventory exposure.

Integrated manufacturing deliverables into new product development process utilizing a PPAP approach and standardizing quality documentation resulting in stabilized time between pilot and mass production.

Implemented tooling standards and analytical molding capability enabling faster product transition.

Created and applied Shingo business assessment tools focused on manufacturing quality across all CMs

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Director Manufacturing Reliability – July 2011 to December 2012

Responsible for brew system quality, consistency, and reliability across a billion dollar multi-tier manufacturing footprint in Southeast Asia and development of a standardized work system, the Keurig Production System.

Strategically collaborated with manufacturing partners and reduced early latency failures by $20 M / year driving a 30% appliance return rate to less than 1.5% of appliances manufactured in 12 months.

Resolved major safety issues through deployment of holistic safety approach based on HPI principles at major supplier site in Foshan, China (Stamping Plant, Final Assembly Plant, and Plastics Molding Plant).

Created strategic response team based on manufacturing centers of excellence in the following areas: Injection Molding, PCBA Processing, Controls, Sub-Tier Development, and Assembly.

Applied safety principles and brought a western safety culture to China contract manufacturing sites and controlled safety through detailed quarterly operational reviews with plant directors in Hong Kong resulting in significant reduction in hand strains and repetitive motion injuries by redesigning fixtures, jigs, work station, and automation of tasks.

Codified business needs into a five year contract manufacturing model across engineering, supply chain, and quality and shifted capital from FOB to full capital control enabling field quality performance improvements.

Linked business analytics and process execution by creation of the Keurig Production System, a common process and systems of standards, which connected the who and what providing a governance model for the Keurig Supply Chain leadership (procurement, quality, manufacturing, planning, logistics).

ADDITIONAL RELEVANT EXPERIENCE

Ocean Spray Cranberries, Lakeview, MA

Director Continuous Improvement

Textron Defense Systems, Wilmington, MA

Director Continuous Improvement

Ford Motor Company, Michigan, Germany: Cologne, and Japan: Hiroshima

Senior Manufacturing Manager – Certified Master Black Belt

Mustang Powertrain Program Manager

Global I4 Product & Manufacturing Business Office Manager

Engine Systems Engineer & Component Design Engineer

General Electric, Lynn, MA

Combuster & High Pressure Turbine Design Engineering

Core Engineer Skills & Foundation – Edison Engineer, GE Aircraft Engines

CONTINUING PROFESSIONAL DEVELOPMENT

Certified Master Black Belt, Ford Motor Co. – Dearborn, MI and Textron – Providence, RI

Certified Lean Sensei, Ford Motor Co. – Dearborn, MI

EDUCATION

Executive MBA, Boston University Questrom School of Business, Boston MA

Bachelor of Science (BS), Mechanical Engineering, Boston University College of Engineering, Boston, MA

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