Continuous Improvement Six Sigma

Charles W. Brown

Fort Wayne, IN ***** 716-***-****

E-mail: **********@*****.*** LinkedIn profile: http://www.linkedin.com/chaswbrown

Dynamic Director of Operational Excellence, Six Sigma Master Black Belt, and Lean Zealot successful at building lasting value for manufacturers. Expert at executing manufacturing systems/processes and Operational Excellence initiatives while enhancing performance, improving quality, reducing costs, and generating Customer Satisfaction through servant leadership with a passion for helping others. Skilled at managing financial metrics with a solid understanding of what it takes to make money. Key qualifications include:

Strategic Business Planning and Deployment

Quality Programs ISO 9001, ISO 13485 & AS9100

Lean Six Sigma Implementations

Customer, Vendor / Supplier Relationships

Advanced Manufacturing Process Introduction

Costing, Margin / Profit Improvement & ROI

Budgeting (Operating/Capital)

High-Performance Team Building; Developing Trust

IATF 16949 APQP, PPAP, Control Plans & PFMEAs

Strong Business Acumen / P&L / Analytics

Major Capital Expenditure Planning, Project

and Program Management

Owned P&L >$100M, Departmental Budgets > $5M and Capital Budgets > $10M

Proven leadership – Successfully led manufacturing teams as large as 400 employees

Multi-site cross-functional experience

Demonstrated a consistent pattern of delivering superior performance

Certified Six Sigma Black Belt and Certified Lean Sensei

Strong technical, analytical, and problem-solving skills

US Citizen with previous Top-Secret Clearances

focused OpEx leader . . . expertise in World Class Manufacturing, Best Practices, TPS LEAN, Demand Flow Technology, 6S, VSM & DMAIC Six Sigma, Standard Work, Theory of Constraints, & GE Change Acceleration Process and all with demonstrated soft skills and an effective decision-making track record with a bias for action

multifaceted strategist . . . looked beyond the status quo to identify and capitalize on profitable opportunities

Career History

Integrated Circuit Works, Warren, IN, Feb 2024-Oct 2024, (Contract Manufacturing, Custom Wire Harnesses, Surface Mount Printed Circuit Board manufacturing, ISO-9001 Certified)

Quality Manager

Completely rewrote the Quality Manual and developed an entirely new set of quality documentation

Developed a new supplier qualification process and quality assessment program for purchasing

ISO Management Representative

Drive ISO 9001:2015 integration across four facilities. Our recent ISO audit had zero non-conformances and zero noted opportunities for improvement.

Wauseon Machine and Manufacturing, Wauseon, OH, 2020-2022, (Contract Manufacturing, Custom Fabrication & Machining, Volume Precision Manufacturing, and Robotic Automation, ISO-9001)

Corporate Director of Quality, Continuous Improvement, and Safety

Leading the Quality Organization, Root Cause Analysis, Continuous Improvement efforts and Safety across three facilities

Partnering with the executive team to create, drive, and promote a “zero defect” mindset throughout the company and to create, drive, and promote a culture of business process excellence and compliance.

Partnering with the executive team to create, drive, and promote a LEAN culture, continuously striving for excellence, and identifying and leading continuous improvement projects throughout the company's multiple manufacturing sites. Developed and released our Manufacturing Quality Guidelines and Supplier Guide

ISO Management Representative (Recent recertification audit with no findings) and OSHA Safety Director

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Intervala LLC, East Pittsburg, PA, 2019-2020, (Contract Manufacturing, EMS, SMT, PCBA, Cable and Box Builds, UL, ISO 9001, AS9100, ISO 13485 Medical Devices, IPC 600, IPC 610, IPC 620, J-STD-001, ESD S20.20)

Director of Operational Excellence / Plant Quality Director

Spearheaded the advancement of the company’s Continuous Improvement initiatives and programs

Strong broad Lean Six Sigma toolbox with theoretical understanding and practical application

Organizational QMS and Product Quality, Incoming Inspection, Calibration, Supplier Quality, In-process, and Final Inspection and a team of four Quality Engineers; Medical IQ, OQ, and PQ Validations; APQP and PPAP

Able to effectively manage multiple complex tasks simultaneously, such as IATF 16949 and AS9100 integration into QMS and the introduction of a new quality assurance module in ERP

Fostered a culture of accountability by creating an environment where my team felt invested in the outcomes of their work through strong communication and interpersonal skills in developing trust.

Cal-Comp USA, Logansport, IN, 2015-2018, (Contract Manufacturing, EMS, SMT PCBA, UL, ISO 9001:2015, ISO 13485 Medical Devices, 21 CFR 820, IATF 16949 Certified, Tier 2 automotive supplier) 400+ associates, 3 shifts

Director of Operations / Site Manager

Drove $50M+ of Revenue with record OTD performance of 64% improvement, 49% improvement in Revenue/employee, 85% reduction in employee turnover, and $70K per month reduction in Overtime

Ability to effectively manage a widely diverse and multi-functional organization leading Product Engineering, Test Engineering, Mfg teams, Engineering, Mfg. Operations, NPI, and Quality

Led management team through the Hoshin Policy Deployment process and development of the company’s KPIs

Instituted and led the Change Control Board and redefined the APQP, NPI process, and process change approval process, and defined the Master Validation Plans

Instrumental in winning new business worth >$30M by reconfiguring the manufacturing floor space

Personally awarded special recognition from a large Customer for teamwork, dedication, technical skills, and trailblazing creativity in the successful launch of their products

Developed the Operational Excellence Program – authored Handbook on Operational Excellence and factory OpEx website, driving positive change in the organization's culture

Demonstrated Communication skills, including author/editor/publisher of a quarterly newsletter focusing on World-Class Manufacturing, Lean Manufacturing, and Six Sigma Methodologies

Implemented Lean concepts factory-wide, including 5S, VSM, Visual Factory, Kanban, and elimination of Waste

MERCURY SYSTEMS, West Caldwell, NJ, 2014-2015, (Military Microwave Electronics, IMAs, SMT, ISO 9001:2008 Certified)

Director of Operations / Director of Quality

Drove $20M+ of Revenue and On-Time delivery using Lean initiatives

Led the Materials, Purchasing, Production Control, Mfg. Engineering, Mfg. Operations and Quality teams

A recognized expert in Solumina paperless Manufacturing Execution System (MES)

Led the management team through the Hoshin Policy Deployment process and developed the company’s KPIs

Provided analytics used in data analysis and Problem-Solving using Minitab and Excel Pivot tables

Developed and implemented the Supplier Assessment program, Lean, and Six Sigma methodologies

TELEDYNE, Rancho Cordova, CA, 2009-2014, (Military Microwave Electronics, TWT’s, ISO 9001, AS9100 Certified, ITAR)

Director of Operations Excellence / Master Black Belt, DOD Secret Clearance

Master Black Belt – providing coaching and in-depth statistical analysis using Regression, ANOVA, and DOE

Executed strategic manufacturing initiatives, including defining and communicating goals, objectives, key metrics, and project management leadership. Implemented plant-wide SPC with electronic data collection

Improved productivity through more capable, robust manufacturing processes and rigorous measurements

$2M savings in Labor and Scrap improvement on one project and an additional $250K savings on another

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Ensured the establishment of manufacturing processes, procedures & controls to ensure on-time delivery of defect-free products utilizing strong technical, analytical, and problem-solving skills

Developed manufacturing standards for First-pass Yield, People involvement, Training, OEE, Production Capability, Cycle Time, Overall Quality, and Delivery. Owned the company’s KPI performance scorecard

Drove financial performance. (Record reduction in scrap performance, Green on all financial metrics)

Lean Six Sigma Implementation, Kaizen, A3, DMAIC, Value Stream Mapping, 5S, Visual Factory, Standard Work, 5-Whys, Takt Time, Kanban, SPC, Cpk, Manufacturing Process Improvement

Investigated, developed, and implemented a Mfg. Execution System (MES); developed the Teledyne University and all associated training materials

Oversaw all Quality functions, including Quality Engineering, Quality Assurance, Calibration, Receiving, In-Process, & Final Inspection

SPRINT, Overland Park, KS, 2007-2008, (Telecommunications and Wireless Data Corporate Operations)

Operations Excellence Manager

Strongly influential in implementing Lean Six Sigma process improvements in Network Operations to reduce Cycle Time and achieved $50M in labor and materials cost savings and $8M savings on another project

Introduced and used simulations to model future state process improvements as part of Value Stream Mapping

Extensive use of Statistical tools to drive fact-based decisions in a Service Industry environment

Trained in and utilized the GE CAP model for Change Management

VICOR, Andover, MA, 2004-2006, (High-volume Power modules and SMT electronics ISO 9000 Certified OEM)

World-Class Manufacturing / Lean Program Manager

Developed Vicor University and delivered associated training materials to develop employees’ understanding of World-Class Methodologies and knowledge base in Lean and Six Sigma. – Still in use today

Led Six Sigma and Lean projects, resulting in large productivity gains and 80% scrap reduction

Developed capacity simulation and planning tools and reduced cycle times by >50% through Lean implementation

Maintained compliance with program plans and schedules, including milestones and performance

Manufacturing Engineering Manager (Vicor)

Led a group of 15 Manufacturing and Process Engineers in support of high-volume Manufacturing Operations

Led team in the process development and conversion to Lead-Free RoHS manufacturing

Drove Continuous Improvement projects through Value Engineering and DFM, resulting in record Quality Yield improvement and $9.6M Scrap reductions

Utilizing Six Sigma & Lean experience provided cross-functional team leadership in Process Controls and Cycle Time reductions. Cycle times reduced from 14 days to 3 days

HONEYWELL FM&T, Kansas City Plant, Kansas City, MO, 2002-2004, (Military Electronics; DOE ISO 9000 and S20.20 Certified manufacturing site)

2nd Level Manufacturing Engineering Manager, DOE “Q” TS / SCI / Sigma 14 / Sigma 15 Clearances

Led 5 Engineering groups, consisting of 8 Engineering teams (100 engineers) supporting 12 advanced electronic manufacturing areas to record-setting financial and quality performance; Drove record performance in Customer Satisfaction, including OTD, RMA returns, and Incentives

A key member of the Technology Council for new technology introduction and Technical Roadmap development

Developed Quality of Events tool used in New Product Introduction for tracking progress to program milestones and use of phase gates in APQP

Led 100 Engineers to certification in Design for Six Sigma (DFSS), totaling over $6,000,000 in savings

Created and implemented Preferred Process Guideline Risk Assessment Tool and DFM guidelines

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CALIENT Optical Components, Ithaca, NY, 2001-2001, (Startup MEMS manufacturing ISO 9000 Certified)

Director of Operations / Quality (the company was purchased and moved to California)

Established and maintained total Quality Assurance / Quality Control program, procedures, and systems per ISO 9000, TL 9000, and company standards.

Managed daily activities of a cleanroom silicon wafer (semiconductor type) advanced manufacturing operations, including facilities engineering and maintenance

Developed and implemented training for Manufacturing, Quality, Safety, and OSHA requirements

MOTOROLA, Elma, NY, 1995-2001, (High volume ISO 9000 / NY State Excelsior Award winner, QS 9000, ISO 14001 / Ford Q1 Certified Tier 1 Automotive electronics) (Plant was acquired by Continental and closed)

2nd Level Manufacturing Engineering Manager

Twice awarded Motorola’s Achievement Award for Total Customer Satisfaction

Managed New Product Introduction (NPI) including a State of the Art $10M fully automated Assembly line

Led outsourcing efforts freeing up 10,000 sq. ft. and reducing overall Conversion Costs to record levels

Developed strong team-building skills necessary to manage and lead multi-disciplined teams

Manufacturing Manager (Motorola)

The leadership of operations of 5 manufacturing teams and 5 engineering teams (350 employees) to record-setting Financial and quality performance (>50% Gross Margin and Zero Customer Defects)

Improved Productivity from 24/7 to 5-day operations while volumes increased from 12M to 20M/year

Instrumental in Business Unit awarded Motorola’s Corporate Quality Award and the Automotive Industries “Quest for Excellence Award”

Ensured the development of detailed plans and financial budgets for the direction and administration of operational business activities, including process engineering, manufacturing, project management, and production support functions to attain objectives based on corporate goals and business plans

Skilled in developing complex manufacturing strategies and proposals

Eliminated $1M in late backlog & $2M in Scrap through WIP reductions as part of TQM, LEAN & Six Sigma implementations

Developed and maintained an effective operations organization through the selection, training, development, compensation, and motivation of all personnel

Recognized as a Subject Matter Expert and Certified as a Six-Sigma Black Belt

Education

Bachelor of Arts and Sciences, Physics, Shippensburg State University, Shippensburg, PA

Additional education from Villanova University (Physics and Lean Six Sigma Certification), Boston University (Project Management), California State University (Electronics), Coastline Community College (Plastics Technology), University of Bridgeport (Operations Research), Worcester Polytechnic Institute (Lean Certification) and Motorola University (Leadership Development and Six Sigma Black Belt Certification)

Professional Development: AMA Executive Leadership, 1100+ hours of Honeywell & Motorola Leadership Training, Certified Six Sigma Black Belt, Certified Lean Sensei, Certified in Business Management Essentials, Certified in Project Management Essentials, Motorola Focus Management Institute, Project Management, Risk Management, APQP, PPAP, GD&T, cGMP, Team-Oriented Problem Solving (TOPS 8D), A3, Pareto 80/20, Total Quality Management, JCIT Demand Flow, TPS Lean Manufacturing, 5S, AGI – Goldratt Institute, GBMP Lean Enterprise, Villanova Lean Six Sigma, Prosci Change Management, GE Change Acceleration Process (CAP), Time Management, Operations Research, ERP training, IMAPS Professional Development Courses, 100+ LinkedIn Learning Courses, Myers-Briggs, Skillsoft, Franklin Covey Leadership Development series and Big Think Softskills, working remotely leadership training, read dozens of books on Leadership and Lean manufacturing, and trained in OSHA CFR Part 1910

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Technical Society Involvement

Awarded “Fellow of the Society” and Life membership – IMAPS, past National Technical Committee member and National Education Chairman – International Society of Hybrid Microelectronics (ISHM), past member of the Board of Directors / VP of Surface Mount Technology Association (SMTA), and current member of Technical Committee. Associate Editor of IMAPS’ Journal of Microelectronics, a member of the International Quality Federation, Assoc. of Old Crows (AOC), Sr. member of the American Society for Quality (ASQ), National Defense Industrial Association (NDIA), and Society of Manufacturing Engineers (SME).

Computer Skills

Windows / Mac – Word, Excel, PowerPoint, Access, File Maker Pro, Project, Outlook & Lotus Notes

Arena Simulation, ProVision, Visio, SharePoint, Quality Analyst, WinSPC, Minitab, TIPQA, uniPoint, 1Factory, MQ1 QMS Systems, MaintainX, Solumina MES, Factory Logix MES, Syteline ERP, HubSpot CRM, Kronos, Paylocity, PAYCOM, Visual ERP, JobBoss ERP & MAPICS ERP, and Remote Communications (Microsoft Teams, Zoom, WebEx and GoTo Meetings)

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