Continuous Improvement Six Sigma, Operations, New Start Up
Resume:
Geronetta K. Fogleman-Green
Millington, TN 38053
***********@*****.***
Professional Summary – Experienced Total Productive Manufacturing professional with over 25 years of experience in both union and non-union facilities, specializing in the areas of Operations, Production, Process Improvement, Continuous Improvement, Lean Six Sigma and Operational Excellence.
EDUCATION
University of Memphis, Memphis, TN
Master of Engineering Technology (Concentration Manufacturing), August 2012
Graduate Certificate – Applied Lean Leadership, December 2011
Major: Applied Lean-Manufacturing Engineering Technology-Continuous Improvement
Master of Business Administration, January 2014 -2015. (18 Hours Completed)
Bachelor of Science in Health Education, May 1993
Major: Health & Safety Minor: Science
MANUFACTURING EQUIPMENT EXPERIENCE
*Automated and Manual Chrome Plating Equipment: Chrome tanks, Transformers, Ovens, Pumps
*Automated Packaging Equipment: Bagger, Case Packer, and Scales
SPECIAL SKILLS
*Lean Certification – 2011.
*Lean Six Sigma – Yellow Belt
*Lean Six Sigma – Green Belt – March 2025
*Lean Six Sigma – Black Belt – December 2026
*Kaizen- Continuous Improvement
*Improving Production with Lean Thinking-Lean Manufacturing
*TOC – Theory of Constraints
*5'S
*TPM
*Motion Study *Excellent Computer Skills
*Excellent Communication, Organizational, and Negotiating skills
*Excellent Presentation Skills-Power Point Presentations
*Excellent Team Building Skills
*Chemical Laboratory Testing-Wet Laboratory Testing
*Environmental Waste Testing in water samples
*AIB Inspection
*Safety & Quality Audits
*Safety Accidents Investigation Experience
*Manufacturing Plant Startup-ISO 9001
*Project Management
*Emergency Medical-Experience
*GMP experience & SQF (Safe Quality Food) experience
*SAP experience & SPC experience
* Center Lining of Manufacturing Equipment- Maintenance & Operations
WORK HISTORY
Globus Medical – Memphis, TN
Continuous Improvement Manager
June 2024 – November 2024
*Lead a team of 4 Process Improvement Engineers.
*Drive Lean Projects throughout the Site yielding Lean Savings over $1 Million yearly.
*Drive a continuous improvement culture, with systems and tools to drive productivity.
*Focus on the people (SME) High Performance Team.
*Realize efficiencies in the operation using Lean Tools (Value Stream Mapping, Root Cause Analysis, PDCA, Fishbone Diagram, 6S, Line Balance, Tier Boards 1, 2, 3 and Daily Hour X Hour boards for Team engagement / communication).
*Provide strategic leadership around initiatives focused on the sustained improvement of business processes.
*Change agent to instill Lean methodology culture and ensure principles are utilized consistently.
*Serves as an expert on Lean process methodology and process improvement.
Rich Products Corporation - Arlington, TN February 2023 – June 2024
Continuous Improvement / TPM Manager
Assist the plant leadership in expanding the implementation of Total Productive Manufacturing (TPM) principles and Lean-Six Sigma capability tools.
*Drive continuous TPM Site Phase progression within all TPM Pillars at the sites this role supports. Including the responsibility for supporting Autonomous Maintenance (AM) / Focused Improvement (FI) / Planned Maintenance (PM) / Early Innovation Management (EIM)/ People Pillar/ Continuous Improvement and Leadership Pillar.
*Execute zero loss analysis and results across plants and the Supply Chain in production, quality, logistics, sanitation and other supporting departments and track results.
*OEE reports to understand capacity constraints and help reduce losses.
*Development of and proficiency of TPM standards and capability builds.
*Train and coach plant associates in TPM processes and systems. Activate skill assessment with Plant Steering Team and Line Trios
*Develop TPM standards that will drive out loss.
*Share and implement Best Practices across the manufacturing Supply Chain.
*Develop business charter for line expansion across network.
Ceva /Ingram Micro - Millington, TN May 2020 – February 2023
(CEVA) BPS Support. (Ingram) Lean Lead (Support North America Network) /Continuous Improvement Manager
*Lean Lead support for all 5 North America facilities with a goal of $5 Million Lean Savings goal. Lean Lead support for all North America with a Total Lean savings goal of $30 Million. Lead the identification, prioritization, and implementation of continuous improvement projects across each of Ingram Micro Mobility operations in Continuous Improvement. Implement the Continuous Improvement system (Lean program) for Ingram Micro.
*Develop sustainable improvements through engagement of a team-based improvement approach and proper use of continuous improvement tools: Kaizen events, 5S, Problem Solving, Fish Bone Diagram, PDCA, DIMAC, White Belt Lean Six Sigma Training, Yellow Belt Lean Six Sigma Training, while building a High Performance Work Team focused on SME that will meet the KPI’s established. Partners with Business leadership to identify and prioritize opportunities to create positive bottom-line growth.
*Support Leaders from each Business unit to engage at a higher capacity and execute the strategy and vision of the business unit. Engage, negotiate, resolve conflict, and build strong consultative relationships and strategic partnerships with senior leaders to facilitate change. Facilitates updates, meetings and key communication with functional managers and executives. Training and mentoring support for the facility.
* Effectively manage a portfolio of leveraged projects to affect the bottom line of the company. Support and show value of CI program through success metrics, value creation (improvements in customer satisfaction, service level, cost, and income). Establishes priorities, determines timeliness of the planning, and conducts the implementation of time, with quality and under budget, while partnering effectively with all stakeholder divisions. Establishes the most efficient processes and tools, in support of the business. Evaluates educational material for Ingram Micro Functional Managers and facilitates the sharing of best practices.
Thyssenkrupp Elevator - Middleton, TN November 2019 – May 2020
Operational Excellence Coach III
Deploy and teach Lean methodologies and principles on a basic level in an effort to determine which methodology applies to any particular problem current or from past occurrences.
*Identify the correct OpEx methodology to improve manufacturing and business processes
Teach OpEx methodologies and principles to all team members and/or cross functional teams
Help identify and prioritize improvement opportunities using a range of methodologies (Visual Management, Mission Control (Raising employee engagement & Satisfaction, Reducing Cost, increasing productive capacity). Coach team members at the operator to manager and director level in Shop Floor Management. Coach team members, functional teams, and cross-functional teams in the methodology of Visual Management (VM), including how to set up VM tools, how to interpret them and how to act on them. Coach and mentor less senior OPEX Analysts and Coaches in all areas of Lean and OPEX methodologies.
*Write new procedures and process instructions on an advanced level. Maintain and improve existing procedures and processes
Prepare reports and training materials in addition to technical reports.
Create and deliver education, training and coaching in a variety of methods: Classroom instruction, Hands-on exercises, Simulations, 1:1, etc.
Act as subject matter expert locally for all Lean Methodologies and Principles.
Work with cross functional teams to develop advanced level solutions for cross functional problems. Develop advanced level solutions for cross-functional problems
Soft Skills coaching and training Multi Project Management Work with Finance department to determine financial benefits of projects, establish tracking mechanisms and be able to address issues. Coach different departments and functions (for example: Manufacturing Engineering, Production Control, Logistics) in Shop Floor Management and Projects execution
Establish correlations between projects and initiatives involving more than one department/function and support Change Management in cross functional projects.
Parker – Hannifin – Batesville, MS May 2017 – July 2019
Value Stream Manager
Manage a team of one Supervisor, six Team Leaders and 105 Operators
Owner of Value Stream P&L’s including cost analysis, product line margin to improve manufacturing productivity. Lean implementation leader showing productivity gains. Leading VSL (Supervisors) & Team Leaders while Training, Coaching, and Mentoring teams to build teams promoting a learning organization. Work with teams to analysis Current State Maps while growing to Future State Map in process and production with outcomes that are sustainable. Work with our Management Team to identify Process Improvement to develop Standardize Procedures to support a Robust System that will maintain the Competitive Advantages. Leader for Kaizen events, Operations Projects, TIB (Team Improvement) Boards, and D x H (Day x Hours) Boards to Target increase production uptime by 10% with every process Improvement. Lead Operations Teams in Root Cause Analysis using Fishbone Diagrams, 5 Why’s, A3, and Decision tree analysis. Leading the Operations Team using a Team Building approach that will produce High – Performance work Teams {HPT- Teams} that generates a World Class Manufacturing Company.
Bosch – West Memphis, AR October 2015 – March 2017
Bosch Production System – Plant Coordinator
Lead the plant in process improvements, plant layouts, and project improvements for all continuous improvements. Train, Coach, & Mentor Managers & Supervisors & Teams in Lean Thinking, Problem Solving, and Root Cause Analysis. Plant Leader for Kaizen events & Kaizen Blitz. Tools used: Fishbone Diagram, A3, PDCA, 6S, and Standard Work.
*Vanguard Soap – Memphis, TN 07/2015 -10/2015
Lean Consultant
*Safety: Accident Investigation, Root Cause of Safety Incidents.
*Changeover Team Leader, Center Lining, & SMED.
*Kaizen Leader: Able to implement Continuous Improvement into the plant.
*Leader in Continuous Improvement promotes an environment of Continuous Improvement, Continuous Learning, and Respect for people.
*Understanding of the Pillars of TPS (Toyota Production System) – able to Implement and design based on the needs
of the Company and the Customer Demand.
*Change Agent: Leader in promoting, setting the atmosphere for Lean, and to embrace change from
“Management to Employee” & “Employee to Management.”
* “Creating an environment of Creativity” & “Motivate and Engage the Team.”
*Strategic Planning for Continuous Improvement using tools:
Kaizen – Lean & Gemba.
* SRC (Single Root Cause Analysis) –Problem Solving.
* Why-Why-Why
*5’s / 6’s
Toyota Production System –Pillars.
AMD (Autonomous Manufacturing Development) / FI (Focus Improvement Leader).
*Value Stream Mapping – “Added Value vs Non – Added Value.” – Remove “Waste.”
*Process Capability –Trend Process Analysis.
Keurig Green Mountain Coffee – Essex, VT December 2014 – July 2015
Production Manager –N2 Shift
*Responsible for the effective leadership and management of manufacturing supervisors - (5 Direct report Supervisors), Trainers, Q.C. Technicians, and 70+ hourly production associates.
*Directs and supports the daily management and prioritization tools to achieve Process Reliability and Production goals.
*Creates a cohesive organization for assigned shift (s) via consent and regular interaction, direction setting and leadership support with shift Supervisors and team members.
*Meets the needs of the customer 100% of the time while achieving key indicator results that support strategic objectives, goals, strategies, and measures (OGSMs) for assigned shift (s).
*Leads failure analysis when required for failures (including near miss and actual incidents).
*Manage data reports, analyze, and provide data to improve operational performance to include OEE, process reliability and labor optimization.
*Leads and develops approximately 5 direct reports (Supervisors -Production) and 70+ hourly team members while fostering a team environment responsible for meeting or exceeding all production goals (safety, cost, quality, service, culture, and strategy).
*Provide direct reports with leadership, direction, and coaching to achieve work objectives and improve performance and skills.
*Develops and inspires others by building and maintaining relationships that motivate the team, guide, and /or reinforce the performance of others toward goal accomplishments.
*Report food safety, quality and regulatory compliance to plant or multi-site leadership with authority to initiate action.
*Works directly with Site Production Manager and cross-functionally with the Engineering, Facilities, Maintenance, Planning, Purchasing, HR, Distribution, Finance, and QC departments to improve quality, streamline efficiency, reduce operating expenses, an improve inventory accuracy.
*Follows all policies, ergonomic standards and safety requirements directed by OSHA, and the department as well as Federal and State regulations which includes the ability to ensure compliance with safety rules and regulations regarding lockout/tag out, hot work, and fall protection.
*Implementation of the DMS (Daily Management System) on the N2 Shift. Coaching, Training to the N2 Leadership Team (Production Supervisors, DC Supervisor, Maintenance Supervisor) of the DMS System for Lean Manufacturing.
Hershey’s – Memphis, TN May 2012 – November 2014
Production Supervisor – Licorice (Candy/Gum)
*Responsible for Packaging and Processing.
*Ensure that the Packaging lines operate at the highest Production, lowest cost, while keeping Safety 1st.
*Leading 1st shift Candy in Team Improvements Strategy using Data, Root Cause Analysis, Continuous Improvement tools (Go-See-Think-Do), Problem Solving Methods (Fishbone, Why’s Why’s), AMD (Autonomous Manufacturing Development, Team Engagement, and Communication.
*Ensure that Safety, Sanitation, Good Manufacturing policies, and housekeeping are followed.
*Identify Improvement and Gaps in the production process and share with peers in order to promote a Lean Thinking culture.
*Ensure that all downtime is entered in SAP, check time keeping system, and check QA paperwork to ensure checks / QA procedure is being followed by operators.
*Identify Cost Savings Opportunities & Increase Production Efficiency.
*Motivate the Candy team during shift huddles and meetings to keep communication open within the department.
*Ensure that Operations and Maintenance are working hand and hand as a team in order to increase Engagement, Lean Thinking / Lean Culture which will lead the Department to World Class Manufacturing.
ConAgra Foods – Memphis, TN June 2010 – May 2012
Production Team Leader – Packaging/Processing
*Relief for the Production Packaging Manager.
*Leader & Advisor to a Crew of 25 Employees.
*Kaizen Leader-Production-Packaging. -Lean
*AMD (Autonomous Manufacturing Development) -Team-Continuous Improvement Coordinator.
*Leading new work system operators-Operation Coordinator, Schedulers, Safety, and Sanitation Coordinators.
*Production Control – Cost, Production Schedules.
*Material/Supply Inventory Control.
*SQF (Safe Quality Food) Coordinator –Production-Packaging.
*Safety Coordinator-Production-Packaging.
*Wastewater Management of the Processing Department.
Alcoa-Kawneer – Hernando, MS June 2007 – February 2009
Supervisor – Packing/Material Handling/Shipping
*Supervise a Crew of 20 Employees.
* Production Control.
*Control the flow of Materials to two different Work Centers-
Paint Department & Anodizing Department
*Safety 1st-Tool Box Meeting.
*Smart-Time Update Daily.
*Continuous Improvement
*Employee Engagement at the Tool Box and on the Floor.
*Shift Safety Audits.
*Mis-Labeled Material Team Leader.
Kellogg’s – Memphis, TN May 1999 – October 2004
Operations Packaging Supervisor
*Supervise a Crew of 35-55 employees. – 2nd Shift Packaging Operation.
*Keeping the packaging area running at the highest Production level & lowest cost.
*Work with packing mechanics and electricians to keep equipment at the highest
Quality standards and adhere to production schedule and improve Quality.
*Work with crew to support Packing Material Utilization keep packing line running
Efficient to reduce material waste: Carton, Liner, and Containers.
*Review all products in Food review to adhere to Customer Satisfaction & Quality Standards.
*Inspect operator reports making sure operators follow Specification.
*Manage Safety Meeting. Meetings include Safety Accidents, Inspection of the
Accident area Develop action items, and resolutions from the Safety meeting.
*Perform GMP, Safety and Quality Audits of all areas: Support Packing Material Utilization.
*Responsible for the S.O.C. (Standard Operating Conditions) & S.O.P. (Standard Operating Procedures) Packing BIB.
*References will be provided upon request*
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