Continuous Improvement Project Management

Charles W. Brown

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

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

Director of Operations with extensive expertise in driving operational excellence and implementing quality initiatives in manufacturing. Leveraging Six Sigma and Lean methodologies, excels at enhancing performance, improving quality, and reducing costs. Committed to fostering a culture of continuous improvement and innovation to achieve strategic objectives.

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, (EMS 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

Implemented a comprehensive supplier qualification process and quality assessment program, enhancing supplier reliability and reducing quality issues

Drove ISO 9001:2015 integration across four facilities. The recent ISO audit had zero nonconformances and zero noted opportunities for improvement

Conducted thorough data analysis of quality metrics, identifying key trends that informed process enhancements and ensured compliance with industry standards.

Streamlined quality control processes, achieving measurable improvements in defect rates and boosting overall product reliability

Fostered cross-departmental collaboration for quality initiatives, ensuring alignment on quality standards and driving shared accountability

Maintained rigorous documentation practices, ensuring all quality records were accurate and accessible, supporting compliance during audits

Mentored team members on quality best practices, cultivating a culture of continuous improvement and enhancing team capabilities

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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

Partnered 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

Implemented LEAN methodologies, enhancing operational efficiency and achieving a culture shift towards continuous improvement across multiple manufacturing sites

Conducted in-depth root cause analyses, leading to effective corrective actions and measurable reductions in defect rates throughout the production process

Developed comprehensive Manufacturing Quality and Supplier Guidelines, standardizing processes and fostering compliance, which contributed to improved supplier performance

Encouraged a culture of safety and quality by mentoring teams, leading to noticeable improvements in workplace safety and employee engagement

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

Implemented Lean Six Sigma methodologies, achieving substantial improvements in operational efficiency and reducing waste across all processes

Able to effectively manage multiple complex tasks simultaneously, such as ISO 13485 and AS9100 integration into QMS

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

Analyzed quality metrics to drive informed decisions, leading to marked gains in product quality and compliance with industry standards.

Orchestrated cross-functional teams to enhance QMS, resulting in streamlined operations and improved stakeholder satisfaction.

Developed a new quality assurance module in ERP, facilitating real-time data tracking and enhancing overall quality management.

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

Effectively managed a widely diverse and multi-functional organization, leading Product Engineering, Test Engineering, Mfg teams, Mfg Engineering, Facilities, Operations, NPI, and Quality

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 and implemented the Operational Excellence Program, fostering a culture of continuous improvement and driving measurable gains across teams

Led the management team in establishing key performance indicators, providing data-driven insights that aligned organizational goals with operational strategies

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Implemented Lean methodologies across operations, driving substantial improvements in waste reduction and operational efficiency

Coordinated cross-functional teams to redefine the APQP and NPI processes, enhancing efficiency and reducing time-to-market for new products, and defined the Master Validation Plans

Spearheaded operational strategies that achieved significant revenue growth, enhancing efficiency and improving overall production timelines

Analyzed performance metrics to identify areas for improvement, leading to streamlined processes and marked gains in productivity

MERCURY SYSTEMS, West Caldwell, NJ, 2014-2015, (Military Microwave Electronics, IMAs, RF, 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’s paperless Manufacturing Execution System (MES)

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

Orchestrated cross-functional teams to enhance operational efficiency, driving substantial improvements in on-time delivery and customer satisfaction

Fostered collaboration among diverse teams to successfully implement Lean initiatives, resulting in optimized workflows and reduced operational costs

Managed the Supplier Assessment program, ensuring compliance with quality standards and enhancing supplier performance metrics

Promoted a culture of continuous improvement through training initiatives, empowering staff, and strengthening overall team productivity

Orchestrated cross-functional teams to improve operational efficiency, driving substantial improvements in on-time delivery and customer satisfaction

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, providing actionable insights that drove measurable gains in operational efficiency

Executed strategic manufacturing initiatives, including defining and communicating goals, objectives, key metrics, and project management leadership. Implemented plant-wide SPC with electronic data collection, enhancing process control and leading to substantial improvements in product quality

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

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

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

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

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Developed and executed a Manufacturing Execution System (MES) that streamlined operations, resulting in marked progress in production tracking and reporting

Coordinated cross-functional teams to establish manufacturing standards, fostering a culture of continuous improvement and ensuring defect-free product deliveryProvided coaching and mentorship to team members, enhancing their skills and fostering a collaborative environment that encouraged innovative problem-solving

Conducted comprehensive statistical analyses to identify inefficiencies, leading to substantial improvements in operational workflows and productivity

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

Used statistical tools to analyze operational data, leading to informed decision-making and measurable improvements in service delivery.

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 SMT 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, Hybrid Circuits; 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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Spearheaded engineering initiatives, achieving record financial outcomes, and enhancing quality standards across advanced manufacturing areas

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) of 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

Implemented data-driven strategies for optimizing assembly line operations, leading to measurable improvements in productivity and quality control.

Manufacturing Manager (Motorola)

The leadership of operations of 5 manufacturing teams and 5 engineering teams (350 employees) to record-setting Financial and quality performance (greater than 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 and $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, resulting in record profit levels

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

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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

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).

Software Skills

Windows / Mac – Word, Excel, PowerPoint, Access, FileMaker Pro, Project, Outlook, 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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