Business Analyst Senior

David Zhang Ph.D., MBB, CQE

*** * **** **, ********, IL 60067 224-***-**** ******@*****.***

Director of Operational Excellence / Lean Six Sigma Master Black Belt / Sr. Principal Engineer

PROFILE

Director of Operational Excellence, Sr. Principal Engineer and Master black belt; Extensive experience in Lean Six Sigma strategic global deployment and training, statistical analysis, and design of experiment; Excellent analytical and practical problem-solving skills with 6-years academic and over 20-years industrial experience plus a history of leading cross-functional teams to identify breakthrough opportunities, jumpstart problem-solving, and drive profit growth across companies for over 50 different manufacturing processes; Proven track record of turnaround, operations excellent, productivity boosting, and cost reduction.

KEY COMPETENCIES & ACCOMPLISHMENTS

Lean Six-Sigma / Process Improvement / Operational Excellence

•The key player in developing two companies into Six-Sigma organizations. Designed and deployed Six-Sigma MBB, BB, GB and DFSS training programs for 2 companies, Trained and coached 43 master black belts, 400+ black belts, and 2000+ green belts.

•Led a multi-functional team that analyzed a distressed MDF manufacture process, increasing line speed by 40%, reducing unscheduled downtime by 22%, and halving downgrade in six months. Yielded a first six months profit increase of $4,750,000 and a total annual profit increase of $14,350,000.

•Conducted the first plant design of experiment in a company history, cutting the percentage of rejection from 6% to 0.1%. This study demonstrated the power of the design of experiment to the company, asked by VP to train all plant technical personnel in design of experiment.

•Led a six-sigma project in two different electronic plants which led to an annual saving of $539,000.

•Redesigned an electric cable production line which cut the WIP by 75% and reduced lead time by 25%.

•Developed a simulation model to study 14 warehouse capacity across the US, Identified the gaps to projected market for each facility, proposed warehouse expansion strategic to prevent possible market share loss, The model also be used to improve production run wheel, changeover, and inventory control.

•Played key role in R&D for gypsum division which successfully completed a strategic transition from paper to glass-mat based products, prevented one plant’s otherwise imminent shutdown.

•Conducted development of lightweight wallboards to counter competitor’s attack on market share.

•Led a major sputtering process improvement project which cut the defect rate over 66%.

•Defeated competitor’s proposal before the American Gypsum Association for a product testing procedure that would have produced strongly adverse results for the company’s products. Defended the company’s interests and prevented significant market share loss.

PROFESSIONAL EXPERIENCE

Littelfuse Inc. Chicago, IL 02/2016-Present

Sr. Principal Engineer / Master Black Belt / Corporate Global Lean Six Sigma Leader

Led the company global six-sigma deployment, design and develop it toward six-sigma organization.

Designed and developed over 20,000+ pages of training materials for Master Black Belt, Black Belt, Green Belt and part of DFSS; Provided 100+ waves of GB, BB, DFSS training in Asia, Europe, and North America for people all across the company; Training and coaching trainer for each region in the company.

Served as a company wise subject-matter expert in lean six-sigma, statistical analysis, design of experiment, process modeling and new product development; Coaching and support major six-sigma projects for all business unit across the company:

oLead a team of 12 engineers, 2 site lean leaders and 20+ change agents engaged in the reed switch process improvement across 3 manufacturing (1 US, 1 Mexico, and 1 Philippines).

oLead and support a team of 2 plant managers, 6 managers and 10+ engineers from 2 manufacturing in China to improve the resistance stability for their major product line.

oLeading and coaching a team of 20+ engineers and managers from 5 facilities to develop 4 key new products using DFSS approach to demonstrate the power of DFSS.

Georgia-Pacific/International Paper/Temple-Inland Inc. Diboll, TX 07/1993-07/2015

Corporate Sr. Project Manager (2013-2015)

Director of Operational Excellence (1995-2013)

Operational Excellence Project Manager (1994-1995)

Research Statistician (1993-1994)

Temple-Inland was acquired by International Paper in 2012 and International Paper was acquired by Georgia Pacific in 2013

Served as a subject-matter expert in system optimization for 14 facilities across the US; Led major production cost reduction initiatives; Risk assessment to major capital investment decisions such as facility shut down, adding a production line and expanding warehouse capacity.

Led the Operational Excellence Group with Temple-Inland to identify breakthrough opportunities, jumpstart problem-solving, and develop applications and systems optimizations across the company; Developed several cutting-edge process control systems and provided risk assessment for major business decisions.

Conducted various statistical analysis, design of experiment, process modeling, forecasting, simulation, optimization, and Lean Six-Sigma projects across the company, saved millions of dollars.

Led and Coached a team of 10+ Master Black Belts spread over 11 facilities; Trained hundreds of managers and technical personnel in Six-Sigma and problem solving skills.

CONSULTING EXPERIENCE

Julian Electric Inc. Westmont, IL 08/2015-02/2016

Corporate Process Improvement Coordinator. In charge of company’s Lean Six Sigma program; Led the redesign of a major cable production line to reduce WIP and cycle time; Developed job-shop schedule algorithm.

Northwest Hardwood Inc. Tacoma, WA 03/2013-06/2013

Director of Operations Research. In charge of company’s operational excellence and process improvement; Simulated material flow, optimized plant layout, and improved productivity.

RELEVANT EXPERIENCE / EDUCATION

Visiting Professor, Statistics Department, University of California at Riverside

Visiting Professor, Statistics Department, Florida State University.

Assistant Professor, Department of Management Science, Shanghai University of S&T, China,

•Executive Certificate, Management & Leadership, Massachusetts Institute of Technology (2007)

•Ph.D., Industrial Engineering, Mississippi State University (1997)

•MS, Statistics, Mississippi State University (1993)

•Master Black Belt / Six-Sigma Champion / Certified Quality Engineer

Contact this candidate