Six Sigma Black Belt

Robert (Bob) Foulks

*********@*****.***

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

Lowe’s Home Improvement LLC, Gun Barrel City, TX. October 2022-Jan 2025

Sales Specialist Hardware and Tools Dept.

Responsible for insuring that all customer are treated as our guests by providing high degree of needs and making sure all their project needs are understood and met. Five time winner of monthly customer excellence vest badge.

Other duties include inventory review and adjustments. Additionally tasked to provide Lowe’s district support to other sites to review issues and provide positive solutions using Continuous Improvement 6 Sigma methods.

Dallas Manufacturing, Athens, TX. July 2020 – June 2022

Billing and Logistics Supervisor ( Manufacturing Plant Closed In Athens )

Responsible for insuring that all customer purchase orders were packed from inventory, routed and scheduled with trucking companies and properly billed once the shipments are picked up. Also responsible for the ECommerce small package department. Direct supervision for eight logistics coordinators. Developed KPI metrics to measure customer order cycle time and quality of order completeness.

Biomerics FMI, Athens, TX. June 2019 – March 2020

Sr. Process Engineer with R/D Department ( laid off due to Covid 19 workforce reduction )

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

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

Industrial Performance Manager (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 that 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. (Plant Closed ) 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.

Prior Experience- RCA/General Electric, Honeywell Int., SGS Thompson, National Semiconductor, Asahi Glass, Graham Packaging.

Military- Served 12 years in USAF- Achieved E-6 rank as a Para Rescue Jumper with Air Search and Rescue and 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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