Six Sigma Applied Science

Location:

Sofia, Sofia City, Bulgaria

Posted:

March 25, 2025

Contact this candidate

Resume:

Denio Chukalov

Bachelor/ Master of Applied Science, 1995

Electronics Engineering

Faculty of Applied Science and Engineering

University of Toronto

Toronto, Canada

Tsvyatko Radoynov Technical School of Mechanical and Electrical Engineering, Kazanlak, Bulgaria, 1989

9 Simeon Veliki Str., Apt. 4

Kazanlak, Bulgaria 6100

email: *******@*****.**; Cell: +359-*********

DUAL CITIZENSHIP: CANADIAN/ BULGARIAN

BULGARIAN DRIVER’S LICENCE

EDUCATION

B.A.Sc./ M.A.Sc. Degree in Electronics Engineering, Faculty of Applied Science and Engineering, University of Toronto, June 1995.

Tsvyatko Radoynov Technical School of Mechanical and Electrical Engineering, Kazanlak, June 1989. Obtained technician’s diploma.

Certified Lean Six Sigma Black Belt (External Certification), Statistical Software MINITAB. Additional training in DOE, Advanced Regression & ANOVA and Advanced Reliability Testing (Accelerated Life Testing).

Train The Trainer Program Certification.

Black Belt: Black Belts are application experts. They are well versed in the Lean, Design for Six Sigma and Six Sigma techniques aimed at process optimization/ excellence and product/ process performance improvement. In addition, they aid and facilitate project teams in Lean, Design for Six Sigma, Define, Measure, Analyze, Improve, and Control with respect to the application of Six Sigma methods for problem solving and new product development. Data-driven decision-making abilities.

SKILLS

Personal: Problem-solver who is self-motivated, proactive, assertive, confident, focused, organized, highly analytical and attentive to detail, and able to work steadily and under pressure to achieve long-term goals. Fast learner with high technical aptitude, which has been proven in my ability to rapidly assume proficiency in state-of-the-art high-tech equipment. Team-oriented, interpersonal, cooperative, conscientious, dependable, and efficient. Excellent communicator. Good multi-tasker able to perform in a fast-paced environment. Strong conflict management and leadership skills.

Languages: English, Bulgarian, Russian.

Lean Manufacturing, Six Sigma, and Advanced Statistical Tools: DMAIC methodology at Black Belt level (Define, Measure,

Analyze, Improve, and Control phases), Design for Six Sigma (DFSS), Robust Design and Optimization Models, Base-lining operational and financial measurements, KPIs, SIPOC, Capacity and Productivity, Process Mapping (BPMN), Value Stream Mapping, Sampling and Inspection Plans, Defective Parts Per Million (PPM), Data analysis, CTQs, Cpk, Ppk, Root-Cause Analysis, Fish-bone Diagram, Risk Analysis, Advanced Reliability Analysis (Apply probability distribution models (Exponential, Normal, Weibull, Log-normal, and Heavy-tailed) for system failure rate modeling). Censored and uncensored data. Survival analysis. Time-to-Failure analysis, APQP, PPAP, Control Plans, 8D, Takt-time and Cycle Time, Kaizen, 5S, 7 Kinds of Waste, SMED, ANOVA, DOE (Factorial Designs, Response Surface Designs, and Formulations & Mixture Designs, Taguchi Static & Dynamic Designs) and Advanced Regression, Spaghetti Diagram, Cell Design, Line Balancing, Pull System, Kanban, OEE, SPC and Control Charts, FMEA, and Gage R&R. Application of statistical methods and performance of mathematical calculations to determine cost of poor quality (COPQ) and evaluate continuous improvement initiatives. Toyota Production System. ISO 9000/ TS16949/ VDA 6.3, FTA. Creating Lessons Learned. PMP/ Prince/ Agile.

Computer: MS Office, MS PowerPoint, and working knowledge of Minitab 16 statistical software. CAD software such as AUTOCAD, CADKEY, and ANVIL 4000/5000. Operation of the WYKO RST Plus Optical Non-Contact Surface Profilometer and its window-based software and data acquisition system. Strong presentation skills and statistical skills.

Materials: Use of microstructure-property relationships, engineering principles, structural mechanics, and stress-strain relationships for design, selection, processing, and analysis of materials. Characterization of microstructure-property relationships for toughening mechanisms and fracture behavior. Composite materials. Engineering ceramics. Electronic materials and principles of semiconductor devices. Band structure and occupancy. Magnetic and optoelectronic materials and devices. Superconductivity. Materials characterization and metallography. Mechanical and metallurgical testing. Gold-sputtering. Laser welding. Soldering. Metallographic polishing and grinding. Nano-hardness testing. Surface characterization using WYKO Optical Non-Contact Surface Profilometer. Microstructure and elemental analysis using an optical microscope, a Scanning Electron Microscope (SEM) incorporating an Energy-Dispersive X-ray (EDX) microanalysis, X-ray Mapping and data acquisition systems.

Machinery and Mechanical: Machining of parts through hands-on operation of machine tools (turning, grinding, milling, and drilling). Selection of materials for machine design. Force analysis and design of shafts, gears and transmission gear box, and disk clutch using CAD software according to ISO standards. Development of manufacturing procedures and selection of tooling for the various types and stages of machining processes involving the above tools. Creation and interpretation of mechanical engineering drawings, geometric dimensions and tolerancing (GD&T), and use of precision measurement tools and metrology. Good mechanical aptitude for assembly and troubleshooting.

WORK EXPERIENCE

2015 – Present

Reichle & De-Massari Bulgaria. Reichle & de-Massari is a leading Swiss manufacturer of passive fiber-optics cabling solutions for high-quality communication networks. With its copper and fiber optic systems the company contributes significantly towards ensuring operational reliability in voice, data and image transmission - worldwide.

Project Lead in Six Sigma and Lean/ Black Belt/ Data & Reliability Engineering Expert/ Tools Expert/ Reliability & DOE Expert/ Coach/ Providing Statistical Support to Team Members/ Facilitator/ Operational Excellence

Responsibilities:

* Acted as a support person providing expert advice to project teams and engineers in the area of Six Sigma and Lean tools as well as statistical analysis (providing statistical support to engineers). Maintained and updated Continuous Improvement Program’s monthly defect trend charts for quantity, frequency, and cost of defects.

* Coordinated, and participated in, Six Sigma and Lean manufacturing projects where I coached and mentored manufacturing project teams in the application of the Six Sigma and Lean methodology, Base-lining operational and financial measurements, KPIs, Capacity and Productivity, Process Mapping, Sampling Plans, Defective Parts Per Million (PPM), CTQs, Cpk, Ppk, Root-Cause Analysis, Fish-bone Diagram, Risk Analysis and Advanced Reliability Testing (Apply probability distribution models (Exponential, Normal, Weibull, Log-normal, and Heavy-tailed) for system failure rate modeling. Survival analysis. Time-to-Failure analysis), 8D, Kaizen, 5S, 7 Kinds of Waste, SMED, VSM, Spaghetti Diagram, Cell Design, Pull System, Kanban, OEE, ANOVA, DOE, 5S, SPC and Control Charts, FMEA, and Gage R&R. Projects were initiated to meet quality requirements formulated by customers.

* Delivered training sessions and coach engineers in Six Sigma and Lean tools - Advanced Reliability Engineering Tools, Robust Design, and Optimization Models.

* Led DMAIC and Lean training sessions as part of Six-Sigma deployment throughout the company in a structured project management framework in process and design environment.

* Collected measurement data. Performed Pareto chart analysis. Created Fish-bone diagrams. Liaised with other departments, such as Engineering, Quality and Production. Monitored operational compliance with the Standard Operating Procedures (SOPs) for a number of process parameters where I prepared reports on process performance and calculated process capability. I also recommended corrective actions and maintained documentation. Conducted periodic status meetings. Acted as change agent and resource to Management. Interacted with shop-floor personnel and process owners.

* Carried out statistical analysis of data with the aid of the Minitab 17 software package, and prepared presentations of reports through the use of MS PowerPoint. Participated in supplier evaluation.

* Applied statistical methods, performed mathematical calculations to determine cost of quality (Profit & Loss), and evaluated continuous improvement initiatives.

* Worked in cooperation with other departments, such as design, quality and production to ensure customer satisfaction.

* Performed additional assignments and duties related to Quality Management Standards (ISO family of standards), Process, R&D, and Design.

* Providing help in the facilitation of problem solving sessions and introduction of problem solving tools. Individual and team coaching by request or observation to help team members develop their methodology and statistics skills.

2009 – 2014

Sensata Technologies Inc./ Sensor-nite, Bulgaria. Sensor-Nite is a Tier 1 Belgian-American manufacturer and supplier of Mass Flow Sensors and High Temperature Exhaust Gas Sensors for the automotive industry. The company is involved in the development of new sensing-technology applications.

Responsibilities:

* Coordinated, and participated in, Six Sigma and Lean manufacturing projects where I coached and mentored manufacturing project teams in the application of the Six Sigma and Lean methodology, Base-lining operational and financial measurements, KPIs, Capacity and Productivity, Process Mapping, Sampling Plans, Defective Parts Per Million (PPM), CTQs, Cpk, Ppk, Root-Cause Analysis, Fish-bone Diagram, Risk Analysis and Advanced Reliability Testing (Applied probability distribution models (Exponential, Normal, Weibull, Log-normal, and Heavy-tailed) for system failure rate modeling. Survival analysis. Time-to-Failure analysis), Kaizen, VSM, ANOVA, DOE, 5S, SPC and Control Charts, FMEA, and Gage R&R). Projects were initiated to meet quality requirements formulated by automakers such as Volkswagen-Audi Group and Daimler AG.

* Delivered training sessions and coached engineers in Six Sigma and Lean tools - Advanced Reliability Engineering Tools, Robust Design, and Optimization Models.

* Led DMAIC and Lean training sessions as part of Six-Sigma deployment throughout the company in a structured project management framework in process and design environment.

* Collected measurement data. Performed Pareto chart analysis. Created Fish-bone diagrams. Liaised with other departments, such as TQM, Automation, Quality and Production. Monitored operational compliance with the Standard Operating Procedures (SOPs) for a number of process parameters where I prepared reports on process performance and calculate process capability. I also recommended corrective actions and maintained documentation. Conducted periodic status meetings. Acted as change agent and resource to Management. Interacted with shop-floor personnel and process owners.

* Applied statistical methods, performed mathematical calculations to determine cost of quality (Profit & Loss), and evaluated continuous improvement initiatives.

* Worked in cooperation with other departments to ensure customer satisfaction.

* Performed additional assignments and duties related to Quality Management Standards (ISO family of standards), Process, R&D, and Design. Participated in bi-weekly teleconference meetings with Dutch and Belgium offices related to ongoing projects.

2008 - Full-time Contract

Stock market investments, Toronto, Ont., Canada.

Industrial Analyst

Responsibilities:

* Analyzed NASDAQ-, AMEX-, and TSE-listed stocks of tech, industrial, and resource firms to invest in. Trading decisions based on a statistical method called technical analysis. Buy and sell signal generated by technical analysis techniques such as Candlestick charting, Fibonacci numbers, Volume, Head-and-shoulders, Flags, Pennants, Triangles, MACD, On-Balance Volume, Wilder’s Relative Strength Index (RSI), Stochastic Oscillators, Williams’ %R, Price Rate of Change, and Money Flow Index.

* Selection also based on research and analysis of the core technical advantages of each company’s product line and the technologies it has adopted.

1995-2007

AMP-Tyco Electronics Ltd.: A multinational corporation, world’s largest manufacturer of electrical/ electronic connectors, headquartered in Harrisburg, PA, USA (it was acquired by Tyco International Ltd. in 1999).

Global Power & Utilities Business Unit, R&D Department, Markham, Ont., Canada.

Responsibilities:

* Supported a variety of customer-oriented multi-task Lean Six Sigma projects and assignments related to the products and components of AMP and its competitors. These included: characterization and evaluation of the electrical contact surfaces of the products through optical measurements of light interference, collection of measurement data, and statistical analysis of the data collected using the WYKO Optical Non-Contact Surface Profilometer; materials characterization (microstructure and elemental analysis) using an optical microscope, a Scanning Electron Microscope (SEM) incorporating an Energy-Dispersive X-ray (EDX) microanalysis, X-ray Mapping and data acquisition systems; and metallurgical and mechanical testing. Participated in new product launches.

* Participated in performance studies, reliability testing, mechanical and electrical testing, statistical non-conformances evaluation, and failure analysis of AMP’s products and materials, and comparative testing and analysis of competitive products and components in industrial environment. Carried out a study to determine the dependence of the electrical conductivity of fired-wedge connectors on the type of grease and size of ceramic grit used in their installation. Gained experience in the installation of these connectors that was part of the procedure required. Fired wedge-connectors are installed using a tool actuated by powder cartridge.

* Supported other R&D activities toward improving the performance of some of AMP’s current products and processes. Was also involved in some equipment calibration. Gained experience operating a vacuum gold-coating (sputtering) chamber in association with some of the projects described above. Became familiar with the operation of a heat-treat furnace, an image analyzer, and a Buehler Micromet II microhardness tester, and with their respective computerized data acquisition systems.

* Was in charge of a project involving surface topography characterization of the contact surfaces of printed circuit boards manufactured by Celestica Inc., which is one of the world’s top electronics manufacturing services (EMS) companies. The results from this project helped Celestica Inc. determine a course of action aimed at improving this particular product. This work further strengthened the department’s role as center of scientific excellence.

* Planned, set up and conducted experiments, collected data and interpreted experiment results, created and maintained records of procedures in relation to each project in a fast-paced environment of changing priorities with very little supervision. Documented results through use of laboratory notebooks, technical memos, and research reports. Assisted in providing for future action to reduce product/process costs and improve products and processes based on the experimental results and findings. Coordinated projects, interfaced with all levels of the organization and personnel (incl. Manufacturing and Quality). Communicated results to Management, related AMP Inc. groups, and inside and outside customers. Prepared project status reports weekly and monthly. Gained excellent project management, communicative, organizational, and technical reporting (verbal and written) skills. The results from all project and research work helped manufacturing and other departments, not only at AMP of Canada Ltd. but also at other divisions of AMP Inc. worldwide.

* Became familiar with the Worker’s Health Management Information System (WHMIS) and the progress of implementation of quality systems and procedures for ISO 9000/9001 and QS 9000 standards at AMP of Canada Ltd.

* Worked in cooperation with other departments to ensure customer satisfaction.

1994 (summer)

University of Toronto, Faculty of Applied Science and Engineering.

Research Assistant

Responsibilities:

* Worked on an industrial project, sponsored by the Ontario Centre for Materials Research (OCMR), whose focus was the experimental analysis of the effect of diffusion barriers, such as nickel plating, on ageing in high-rupture-capacity fuse components manufactured by Nor-Am Ltd. (an Ontario company) using soldering. Performed metallurgical testing, and microstructural and elemental analysis using optical microscope and SEM/EDX on numerous samples.

* Prepared and submitted a final report with the findings to Nor-Am, which helped them resolve process design problems related to their soldering process.

AFFILIATIONS

Member of the American Society for Metals (ASM) International – Materials Information Society (Society for Materials Engineers).

OTHER INTERESTS

Reading in the subjects of international business, banking, economics and commerce; playing tennis and soccer.

REFERENCES AVAILABLE UPON REQUEST

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