Quality Control

George Varghese

**** ******** *****, ******* ***, CA 95746

661-***-**** ******@*****.***

linkedin.com/in/k-george-varghese-52a8376

SUMMARY

Professional manager with over 20 years of experience improving safety, productivity, efficiency, and quality in service delivery/manufacturing/production operations. Key achievements include:

• Enhanced workplace efficiency with 5S program.

• Absenteeism reduction within eight months.

• Monitored quality processes for an innovative project, achieving a significant reduction in fault rates.

• Promoted team building, training, and leadership for employee development and performance excellence. EXPERIENCE

Production Manager ALSCO, Sacramento, CA 08/2023 – 11/2024 Championed facility safety protocols, streamlined operations, and implemented hiring strategies while managing scheduling and quality control processes; enhanced workplace efficiency by establishing a robust 5S program that improved organization.

• Analyzed reporting processes, pinpointing inefficiencies that led to inaccurate metrics; restructured workflows and bettered data integrity, resulting in a 25% improvement in report accuracy for upper management.

• Spearheaded training programs designed specifically for high-impact roles within operations, enhancing overall team capabilities while mastering two key operational tasks within 4 weeks; refined overall competency level by enabling multi-role capability across departments.

• Cultivated confidence among Lead personnel through targeted training sessions on data driven decision making techniques, which resulted in clearer communication strategies within teams and decreased miscommunication incidents.

• Engaged daily with Engineering personnel to identify bottlenecks; monitored PM processes that fixed overall machinery performance by enhancing increased productivity.

• Effective communication in a unionized workforce setting, resulting in 85% reduction in absenteeism within eight months.

• Conducted hands-on coaching to specifically enhance employee competencies related to production efficiency metrics; personally trained over ten new hires who achieved full productivity targets within just eight weeks post-training completion.

• Orchestrated the 1.8 days ahead strategic planning initiatives, resulting in a cumulative increase of efficiency from 1.2 to 1.6 days ahead of schedule.

Facility Safety and 5S Coordinator ALSCO, Sacramento, CA 08/2021-08/2023 Spearheaded plant safety protocols and followed 5S Lean methodology, enhancing production quality for an industry certified linens operation that served over 500 clients in healthcare, restaurants, and other businesses across Northern California.

• Coordinated daily meetings with operational leaders to identify improvement areas in production practices; drove initiatives that reduced Total Recordable Incident Rate by 20%.

• Revamped operational procedures and delivered comprehensive training programs, resulting in a 50% increase in production efficiency while fostering clearer communication and accountability across the workforce.

• Arranged cross-departmental workshops to reinforce understanding and implementation strategies concerning updated operating procedures; increased employee participation rates in these training courses by over 90%.

• Led efforts alongside cross-functional teams focused on improving safety standards during incident investigations while launching innovative HSE programs that achieved in maintaining zero major injuries over 150 days.

• Introduced the TAKE TWO protocol and BBS (behavioral-based safety) framework in Sacramento, leading to a K. George Varghese, page 2

more structured approach for identifying hazards and enhancing employee engagement regarding workplace safety practices.

• Led cross-functional workshops discussing findings from accident investigations focused at addressing top three causes of unsafe conditions directly impacting employee engagement around safety practices throughout the shift.

• Planned strategic initiatives to improve operational guidelines, resulting in 100% adherence to regulatory requirements across all departments, while maintaining rigorous documentation practices. This led to TRSA and NSF re-certification, satisfying standards for hospital and F&B business respectively. Manufacturing and Quality Assurance Engineer Kreysler and Associates, Vallejo, CA 06/2019-04/2021 Devised quality control processes for the manufacturing of the world’s first FRP (fiberglass reinforced polymer) building facade, ensuring compliance with rigorous standards for the Los Angeles Lucas Museum of Narrative Art.

• Pioneered 5S, Kaizen, NCR methodologies, Gage R&R for Faro CMM systems and Value Stream Mapping

(VSM); trained over eight personnel on Lean manufacturing tools to elevate operational efficiency by decreasing waste across production lines.

• Collaborated closely with stakeholders from three separate firms to outline design specifications for the new building facade project; managed an impressive reduction in defect occurrences throughout the fabrication phase.

• Executed comprehensive audits of individual production cells, ensuring adherence to established quality standards; had a significant 30% reduction in fault rates and higher process reliability.

• Engineered a comprehensive system for managing tools within a specialized tool room, which facilitated effective tracking and accountability; reduced time wasted on locating equipment to less than two minutes per instance.

• Revised comprehensive training materials that ensured successful onboarding of six quality control employees in compliance with SOPs. This facilitated measurable improvements in reduced time to competency by an average of 30%.

Service Quality and Training Leader Allied Horizontal Wireline Services, Houston, TX 10/2013-04/2016 Directed a team of 12 Service Quality and Training members in executing initiatives across eight districts, ensuring tailored solutions to meet the unique needs of demanding client bases while maintaining high service standards.

• Mapped out essential KPIs dedicated exclusively to monitoring machinery uptime versus downtime ratios; got an increase in equipment availability reaching over 97%, directly influencing service quality satisfaction among clients served daily.

• Facilitated kaizen blitz audits designed to enhance service quality while reaching an operational efficiency rate of 98%; these efforts directly contributed to better customer trust and greater client loyalty.

• Negotiated favorable contracts with key vendors, achieving savings exceeding $2M annually while securing advantageous terms that bolstered competitive positioning within the industry.

• Facilitated comprehensive classroom sessions alongside hands-on training modules; authored operations manuals and produced instructional videos helping to consolidate employee skills development. Technical Manager/Field Service Coordinator Halliburton Energy Services, Bakersfield, Thailand, Nigeria 05/2003- 09/2013

Streamlined quality service delivery with efficiency and safety across three product lines serving oil and gas companies globally. Promoted from Operations Engineer to functions with higher accountability including training, safety, technical and quality management, operations management, and business development. Capitalized on two decades' worth of international exposure serving oil and gas industry across continents by providing exceptional performance standards that enriched stateside projects with globally informed perspectives.

• Developed comprehensive training programs for over 50 Engineers and 90 Operators across eight countries, fostering skill enhancements that led to a marked decrease in operational errors during field service activities.

• Launched revisions of equipment functionality which minimized non-productive time (NPT), leading to boost performance metrics, and sustained operational efficiency at 98%.

• Conceptualized the 'condition-based maintenance' and 'cruise control' strategies to Corporate Technical K. George Varghese, page 3

Services, facilitating 100% reliable data acquisition in low resistive well formations.

• 85% success in integrating and streamlining a newly acquired fiber optic company to all corporate standards within two years. Planned and deployed StimWatch fiber optic project that received global recognition and became a significant revenue generator.

• Completed strategic initiatives focusing on SOX adherence during internal audits which led directly to achieving zero non-compliance incidents, reported throughout three consecutive annual evaluations.

• Scheduled hands-on mentorship during 5S initiatives by developing training materials resulting in a reformed workspace organization scores from audits done at two distinct facilities within the region. EDUCATION

MBA: University of California, Irvine

BS Engineering (Electronics): Bengaluru (Bangalore) University, India Certifications and Technical Skills

• ASQ Certified Manager of Quality/Operational Excellence (CMQ/OE - expired).

• ASQ Certified Quality Auditor (CQA- expired).

• ASQ Six Sigma Green Belt (SSGB).

• ISO 9001:2015.

• Six Sigma Black Belt (non- ASQ).

• Business Data and Analytics.

• MS Office.

• Minitab.

• TapRoot Analysis.

• SAP Navigation.

• Basic knowledge of C/ Salesforce/ Python/R.

• Illinois Tech/Edureka Post Graduate Certificate Program in Generative AI and ML (ongoing).

• MLOps Certification Course (ongoing).

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