Continuous Improvement Project Management

Michael Joy

************@*****.*** Ph: 574-***-****

Quality, Operations and Continuous Improvement Leadership

Qualifications include; a Master’s Degree in Manufacturing Management, a Bachelor’s Degree in Physics and Mathematics, a Black Belt in Lean/Six Sigma, a demonstrated ability to form, lead and develop high-performing teams and process in a variety of manufacturing scenarios including outsourcing and insourcing.

Highlighted Skills

Turnaround Management and Organization Development

Quality Management System Development

Lean Thinking and Continuous Performance Improvement

Factory Expansion, Outsourcing, and Insourcing

Project Management and PMO Leadership

Software Development and Global Deployment

Task Force and Kaizen Event Leadership, Analytics

Lean Manufacturing, Theory of Constraints, Six Sigma

Data Based Goal Setting and Performance Monitoring

Customer and Supplier Relationship Management

Experience

Quality Manager and Continuous Improvement Leader 10/2018 to 11/2019

Restoration Medical Polymers – Medical Device Start Up (ISO-13485) Columbia City, IN

Primary responsibility to lead the Quality Management System creation and implementation in a startup UHMWPE (polyethylene) resin blending, extrusion and compression molding facility for the medical device manufacturing industry. Leadership responsibilities also include; Lean and visual factory, process validations, supply chain, MRB/DRB, CAPA management, package / ship process development, and Document Control in an FDA Regulated industry (ISO-13485).

Impact: Developed QMS for startup organization including ISO-13485 certification, (0 findings!), hosted customer audits created CAPA, MRB, calibration, 5S systems. Facilitated Kaizen events and excursion task force leadership.

Quality Consultant 10/2017 to 8/2018

Techniplas / Nyloncraft – Automotive / Medical Device (TS16949, ISO-13485) South Bend, IN

Responsibilities included customer support (Ford, Stryker, GM, Firestone) and CAPA response for injection molded plastic components and assemblies.

Impact: Achieved a 60% improvement in customer complaint response time and a 40% improvement first pass customer CAPA acceptance. Affected production processes and created benchmark Work Instructions, FMEAs and Control Plans to ensure generational learning with compliance to industry standards. Measurement System Analysis, Gage R&Rs, DOEs and process capability analysis. New product launches through the PPAP/APQP process including capacity studies.

Continuous Improvement Engineering Manager/PMO Leadership 4/2014 to 3/2017

Zimmer Biomet – Medical Device (ISO 13485, ISO 9001) Warsaw, IN

Responsibilities included leadership of advanced manufacturing engineering team created to drive improvements in the existing productions systems and the development of the project management office to ensure on time and on budget, mission critical projects. Engineering Management – Led a team of engineers focused on improving performance and capacity for critical production processes. Drove cultural migration toward continuous improvement with deployment strategy, training, and metrics. Project Management Office - Developed project management office for North American Operations including processes for setting strategic goals, reporting performance, capital acquisition, project prioritization, project management coaching.

Impact: 21% increase in volume and 69% reduction in lead time for flagship medical device. Created a culture of continuous improvement with accountability. Partnered with Finance and achieved $100M in savings over three years.

Vice President (Technical Excellence) 2/2011 to 1/2014

ZERO Cases Manufacturing- Automotive / Military / Aerospace / Oil-Gas North Salt Lake, UT

Direct responsibility for the safety and performance of 60 employees providing protective solutions for customers that included NASA, Lockheed Martin, Boeing and our armed forces. Leadership responsibilities included Engineering, Quality, Maintenance, Planning, Inside Sales, and Customer Service. ISO 9001, TS16949, AS9100, MIL-Spec, ITAR.

Impact: Transformation of culture and morale. Reduced design lead time from 43 to 9.2 days, created new product designs and business wins, improvements in first pass yield (CNC, waterjet, heat treat, anodizing, chem film, paint and powder coat). Implemented ERP system (SAP with DBR+). Expanded engineering & chemical testing lab in 300k sq. ft. industrial manufacturing facility.

Operations Manager and Manufacturing General Foreman 1/2007 to 11/2010

Fairchild Semiconductor – Electronics / Automotive (TS-16949, ISO 9001) West Jordan, UT

Direct responsibility for the safety and output performance of 150 employees in a 120,000 sq. ft. cleanroom facility.

Impact: Achieved a 40,000 square foot cleanroom expansion, deployed Six Sigma/Lean/5S program. Accomplished a 208% increase in production start material and 6% improvement in constraint performance each with $0 capital/expense.

Director of Quality 9/1995 to 12/2006

Intel Corporation – Electronics / Automotive Hillsboro, OR

Direct responsibility for the Supply Chain Quality Management System and $7B in spends over the indirect materials organization in the high technology world of semiconductor manufacturing. Implementation of Lean/Six Sigma. Operational excellence strategy development and quality leader in pursuit of equivalent Malcolm Baldrige award.

Impact: Achieved Intel Quality Award. Deployed Lean/Six Sigma methodologies achieving holistic supplier performance improvement and millions in cost savings. Developed, deployed Supplier Continuous Quality Improvement program in a global organization. Created & deployed eAudit software achieving Intel software quality award.

Production Value Stream Manager directly responsible for the safety and performance of 3 semiconductor manufacturing departments consisting of 50 employees in a self-sustaining 24 x 7 global manufacturing environment. I had direct ownership of profit and loss, manufacturing process performance/quality, organizational development, equipment and facilities maintenance. Continuous improvement driving performance to meet division goals.

Education

Master of Science – Manufacturing Management/Engineering Science Rensselaer Polytechnic Institute (RPI)

Bachelor of Science – Physics and Mathematics S.U.N.Y. Plattsburgh

Six Sigma and Lean Black Belt Arizona State University & Six Sigma Registrar

MTP – Managing Through People Intel’s Management Training Program

Community Impact

Adjunct Professor – Sharing competencies related to Continuous Improvement and Design for Manufacturability

iHIP Mentor – Internship mentor for gifted High School students

Mayor’s Youth Council Advisor –Created the Mayor’s Youth Advisory Council for the City of Warsaw, IN.

Boy Scouts of America - Scout Leader coaching and mentoring the future leaders of America.

4H Robotics Club - Started a robotics program for the youth of Kosciusko County, IN.

United Way - Team Leader and regular volunteer making a difference in the community.

Make-A-Wish - Project Foreman making a difference in the community.

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