Quality

James C. Shea

Phone: 321-***-****

E-mail: ******************@*****.*** **************@*****.***

Operational Excellence and Continuous Improvement Leader with 26 Years of Cross-Industry Experience delivering transformative results across aerospace, defense, healthcare, and manufacturing sectors

A transformational leader and Lean Master Nominee with 26 years of operational excellence expertise, 18 years leading enterprise Lean transformations, and a proven track record translating complex methodologies across aerospace, defense, healthcare, and manufacturing sectors, delivering Multi-million dollars in quantifiable business impact. Successful at leading enterprise-wide change by aligning strategy, people, and process to improve safety, quality, delivery, and customer experience; translating operational systems into practical, human-centered solutions that improve frontline execution and stakeholder confidence. A personable leader, adept at leading cross-functional teams, facilitating Kaizen events, coaching leaders, and communicating value across technical and non-technical audiences, leveraging a strong service mindset shaped by military aviation, continuous improvement leadership, and direct customer-impact initiatives, with growing emphasis on customer engagement, training, and influence-driven communication.

Areas of Expertise:

Operational Excellence Lean Six Sigma Continuous Improvement Customer Service Excellence Process Transformation

Value Stream Mapping Kaizen Facilitation Cross-Functional Team Leadership Training & Coaching Manufacturing Excellence Healthcare Process Improvement Supply Chain Optimization Root Cause Analysis Process Standardization

Stakeholder Engagement Performance Metrics & KPIs Service Delivery Improvement Technical Communication & Education Business Process Reengineering TPM & 3P Methodology Hoshin Kanri Policy Digital Content Strategy

Summary of qualifications

Delivered measurable operational improvements across aerospace, healthcare, electrical manufacturing, and defense sectors, maintaining exceptional service and operations delivery standards and stakeholder satisfaction.

Consistently achieved customer satisfaction improvements, including increasing On-Time Delivery from 92% to 100%; training over 1,793 employees, and achieved a 6.5 out of 7 transactional survey score.

Generated over $53M in forecasted savings and $1.1M in cost avoidance through process redesign, inventory optimization, and operational excellence initiatives, consistently delivering ROI-focused solutions that enhance value and profitability.

Demonstrated exceptional leadership and placed as a Raytheon Technologies Lean Master nominee, led the site to first place in Collins North America ACE IT competition, and received dual Sikorsky Aircraft Rescue Awards for excellence.

Created "Plan for Every Pill" (PFEP) initiative, adapting aerospace Lean principles to healthcare medication management across 22 facilities, addressing patient safety, nurse efficiency, and service delivery excellence.

Profound at building stakeholder relationships, facilitating cross-functional collaboration, and driving organizational buy-in through effective communication, training delivery, and translating technical concepts into actionable insights for diverse audiences, including executives, frontline staff, and external clients.

Professional Experience

Lean Six Sigma / OpEx Consultant

Gardner Resources Consulting, LLC April 2025 – June 2025

Created industry-first "Plan for Every Pill" (PFEP) initiative, adapting aerospace Lean Six Sigma strategies to the healthcare sector, ensuring full medication visibility and traceability from supplier to patient across 22 facilities while improving nurse workflow efficiency and patient care experience.

Engineered a comprehensive medication security solution integrating leading healthcare technologies, including Omnicell Automated Dispensing Cabinets (https://www.omnicell.com/points-of-care/xt-anesthesia-workstation/) and Snap-on Tool Control Systems Level 5™ (https://www.snaponlevel5.com) with barcode-driven workflows addressing medication security, nurse efficiency, medication diversion prevention, and patient safety through customer-centric design principles.

Documented significant operational deficiencies through detailed time studies tracking pill flows, med-pass timing vulnerabilities, refill delays, and potential diversion risks while engaging frontline healthcare staff to understand customer service pain points across 22 CVS Omnicare facilities

Mapped complete value stream from supplier shipment to bedside administration, capturing nurse handoff patterns, medication return loops, and refill inefficiencies with actionable improvement recommendations focused on enhancing patient and healthcare provider experience.

Designed a multi-phase implementation strategy featuring gap analysis, mock simulation, pilot deployment, and full rollout plan with facility selection criteria based on risk exposure, volume, and organizational readiness while building stakeholder buy-in through effective communication.

Integrated cutting-edge technologies, including pill-level barcoding, Snap-on ARC secure storage with badge authentication, Omnicell automation integration, Lean Kanban inventory restocking, and error-proof scanning systems, create unit-level traceability, preventing waste, loss, and harm while improving customer service reliability.

Electrical Sector OPEX / CI Manager / Americas

Eaton January 2022 – July 2023

Directed operational excellence and continuous improvement initiatives across North America, Central America, South America, and the Asia Pacific regions for electrical manufacturing operations.

Identified and forecasted savings exceeding $53M through strategic manufacturing cell redesign, relocating one employee 18 feet, and adding a conveyor system on a high-impact, low-cost innovation that improved customer delivery responsiveness.

Achieved 50%+ improvements in On-Time Delivery (OTD), Lead Time, Productivity, and Inventory reduction (5 hours of stock), directly reducing overtime costs and enhancing customer satisfaction through reliable service delivery.

Redesigned the mix model value stream manufacturing cell, optimizing product mixes based on current and future demand forecasts, increasing operational flexibility and customer responsiveness to changing market requirements.

Conducted 72 comprehensive process time studies in Meter Line, establishing performance baselines and identifying improvement opportunities through data-driven analysis focused on customer value delivery.

Eliminated D.O.W.N.T.I.M.E. waste (Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, Extra processing) through inventory reduction and process streamlining, enhancing customer experience.

Applied 3P (Production Preparation Process) methodology, validating and implementing cellular redesign, ensuring sustainable operational improvements, scalability, and consistent customer service standards.

CI, Manager / Executive Leadership Lean Master Nomination

Collins Aerospace February 2020 – January 2022

Led Site Lean Transformation Project containing 19 Kaizen events, bringing the site to win first place in Collins North America ACE IT competition, demonstrating exceptional operational leadership and commitment to customer excellence.

Facilitated annual enterprise Hoshin Kanri "Policy Deployment" strategic initiatives aligning cross-functional teams with organizational priorities, measurable performance targets, and customer satisfaction objectives.

Conducted 160 time studies across 8 different processes (20 people each), establishing comprehensive performance baselines and identifying systemic improvement opportunities focused on enhancing customer value delivery.

Reduced Fusion Cell process variation by 30% enhancing product quality consistency, reducing rework costs, and improving customer satisfaction through reliable product delivery.

Decreased production work shifts from 3 to 1, optimizing workforce utilization and reducing production overtime by 50% generating $52K annual savings while maintaining customer service levels.

Improved Cell Capacity by 15% achieving $200K WIP reduction annually while reducing part transportation distance by 3,694 miles, saving $36K annually, and improving customer delivery speed.

CI Manager / Aftermarket Overhaul & Repair

Pratt & Whitney May 2017 – January 2020

Designed and implemented Mixed Model Cellular Design, doubling annual P&W V2500 engine volume from 25 to 50 units, increasing Return on Sales (ROS) from 25% to 35% and generating $1.05M in annual sales benefits.

Led TEC engine Setup Reduction Kaizen event, reducing machine changeover time from 270 minutes to 60 minutes (210-minute reduction), generating $327.6 annual savings and improving customer delivery responsiveness.

Conducted LPT Mixed Model Value Stream Mapping, reducing product Lead Time by 3.75 days and Processing Time by 3.67 days (7.42 total days), cutting processing steps from 43 to 33 and reducing inventory by 8 WIP pieces.

Led Diffuser Mixed Model Value Stream Mapping, reducing product Lead Time by 12 days and Processing Time by 0.5 days, achieving total time reduction of 12.5 days, improving customer satisfaction through faster delivery.

Conducted a minimum of 34 time studies documenting process performance baselines and led 34 lean manufacturing Kaizen events, including 3P, Setup Reduction, Shared Services, Root Cause Analysis, TPM, 5S, and Benchmarking, focused on value.

Managed 10 certified Lean Champions developing organizational self-sustainability through coaching, formal training, Kaizen event leadership, and mentoring programs focused on customer experience excellence.

Lean Transformation Coordinator (ACE) / Aircraft Manager

Sikorsky Aircraft September 2007 – October 2015

Trained 1,793 employees in Lean methods across Business Process, Operations Management, and Supply Chain, achieving a transactional survey score of 6.5 out of 7, demonstrating exceptional training effectiveness and customer service commitment.

Generated total cost avoidance of $1.1M through Quality Clinics, Root Cause Corrective Action, Kaizen, 3P, TPM, and Value Stream Mapping events focused on Safety, Quality, on-time delivery, cost savings, and customer satisfaction.

Led Final Assembly S-92 floor panel defect reduction project, achieving $1.052 cost avoidance through systematic quality improvement and defect prevention strategies, enhancing customer product quality

Conducted Paint Shop 5S/6S Kaizen event, maximizing floor space utilization, generating $68.8K savings through workplace organization and visual management, improving workflow efficiency, and customer delivery

Co-led FAA and ISO 9100 internal and external audits, maintaining a zero major findings/violations record, demonstrating exceptional quality systems management, regulatory compliance, and customer confidence.

Co-led International Trade Compliance audit processes, ensuring regulatory adherence and risk mitigation across complex international operations while maintaining customer trust and service reliability

Championed Customer Feedback Analysis and Process Maturity development utilizing TQM tools to identify, trend, and forecast internal/external customer feedback, driving continuous improvement and service excellence.

Research and Development Technician

DynCorp International January 2007 – May 2007

Conducted Phase A, B, C, D Pre/Post flight and Master Phase inspections on VH-UH/SH-3H, AH-1W, CH-53, H-60 (R&S models) rotary wing aircraft, ensuring mission readiness, safety compliance, and customer operational requirements.

Replaced and maintained critical aviation systems, including engines, gearboxes, fuel systems, and rotor assemblies, maintaining fleet operational availability and customer mission success.

Conducted and analyzed vibration analysis of rotor track and balance using Automatic Track & Balance Set (ATABS), ensuring aircraft safety, performance standards, and customer confidence.

Aviation Analyst

Aviation Research Group January 2005 – December 2006

Developed Charter Evaluation Qualification Reports (Cheq Reports) containing pilot certificates, aircraft registrations, operator certificates, accident/incident reports, enforcement actions, and ownership information for FAA Part 135 charter operators.

Analyzed and processed D-085 charter operational specification certificates, updating Checkmate database containing data for 979 charter operators, 12,771 pilots, and 3,663 aircraft, providing reliable information to aviation clients.

Collaborated with Part 91 vendor standards and crew scheduling teams, ensuring established safety and operational requirements were consistently met while maintaining strong customer relationships.

Naval Aviation Helicopter Rescue Swimmer & Flight Operations Crew Chief

United States Navy January 1999 – January 2007

Performed critical Search and Rescue (SAR) operations responding to emergencies at sea, including life-threatening medical evacuations and pilot recovery missions, demonstrating exceptional customer service under extreme pressure.

Executed successful Medivac from USS Kauffman, recovering Command Master Chief from life-threatening injuries, demonstrating exceptional technical proficiency, composure under pressure, and commitment to service excellence.

Performed F-14 Double Ejection rescue operation, recovering both pilots who successfully returned to flight duties, showcasing mission-critical aviation rescue capabilities and life-saving customer service.

Supported military operations and training exercises throughout all flight operations leading up to, during, and post-September 11th, demonstrating operational flexibility, mission commitment, and service to the nation.

Education & Certifications

Master of Science in Quality Systems Management Cambridge College

Bachelor of Science in Professional Aeronautics Embry-Riddle Aeronautical University, Daytona Beach, FL (2004)

Associate Degree in Aviation Safety Embry-Riddle Aeronautical University, Daytona Beach, FL (2002)

Project Management Certification Villanova University, Villanova, PA (2012)

Six Sigma Black Belt Training Villanova University, Villanova, PA (2011)

Lean Six Sigma Certification Villanova University, Villanova, PA (2010)

Red-X Apprentice Shainin (2017)

Awards & Honors

Raytheon Technologies Lean Master Nomination:

Recognized for exceptional operational excellence leadership and transformative results.

United Technologies ACE Practitioner (Operations):

Certified in Achieving Competitive Excellence operational methodologies.

United Technologies ACE Practitioner (Business Process):

Certified in business process improvement and organizational transformation.

Sikorsky's Aircraft Rescue Award (2 Awards):

Received two separate awards for exceptional Search and Rescue missions flown.

Nominated for Sikorsky Aircraft Presidential Award 2011:

Recognized for outstanding contributions to organizational excellence.

Navy / Marine Corps Achievement Medal:

Awarded for meritorious achievements during military service.

Department of Transportation Instructor Certificate:

Operational Risk Management (ORM).

Technical Skills

Enterprise Systems: MRP, SAP, Solumina, MS Project, Crystal Viewer

Analysis & Design Tools: Minitab, VISIO, SharePoint (Power User & Web Development)

Quality Standards: AS9100, ISO 9001, FAR Part 91/121/135/14

Technical Skills: Blueprint/Drawing Interpretation, Aviation Maintenance/Repair Procedures

Microsoft Office Suite: Advanced proficiency across all applications

References

Available on request

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