Manager Six Sigma

JOHN SPAYDE

** ****** **** *****

Greer, South Carolina 29651

[864] 895-5564 (Home) [740] 361-3498 (Cell)

*******@*****.***

OBJECTIVE:

Manufacturing Engineering Manager, bringing 18+ years of experience and skills in engineering, program development, maintenance, lean manufacturing implementation and six sigma black belt methodology. Driver of change in safety, quality, production and delivery issues.

Product Design - Continuous Improvement - Lean Manufacturing - Root Cause Analysis

Staff Development - Six Sigma - Strategic Planning - Process Development - Program Management

Value Stream Mapping - Standard Work - Cellular Manufacturing - 5S - Visual Management

PROFESSIONAL EXPERIENCE:

Manufacturing / Lean Engineer, Watts Regulator, Chesnee,SC 2010 – 2012

- Continuous Improvement implementation in a brownfield facility, conducted gemba walks, lean

training, kaizen blitzs, value stream mapped manufacturing and transactional processes, developed standardized work and visual work documentation.

- Reduced raw material inventory by $1.5 million in 6 months time, using visual controls / kanban.

- Created production cells, that were autonomous to the manufacturing facility, utilizing cyclical visual scheduling and supermarket systems, which eliminated inventory and delivery issues.

- Worked with Value Stream managers to identify root causes of safety, quality, delivery and

productivity issues, conducted capability studies, resulting in sustainable improvements in all areas.

Engineering Manager, CVG Trim Systems, Statesville, NC 2007-2009

- Managed a team of engineers and maintenance technicians that concentrated on process design, implemented strategy for equipment modification, resulting in increased process reliability and output.

- Focused on operating issues by introducing safety stop and process check techniques that reduced the frequency of recordable accidents by 85%, and reduced operational wastes by 25%.

- Achieved equipment reliability and maximized equipment up time through implementation of TPM system focusing on preventative/predictive techniques, autonomous checklists and statistical analysis.

Lean Manufacturing / Engineering Mgr, Coupled Products Inc., Upper Sandusky, OH 2001–2007

- Led value stream mapping team reviewing all processes, developed deployment plan, followed up to insure that future state was achieved, eliminating non-value added operations, reducing delivery time and operational costs.

- Managed cross functional team to develop poka yokes and vision detection systems, eliminating the need for workers to conduct manual 100% inspection of product (visual and gauges).

- Concentrated on process monitoring efforts, involving tool life and broken tool detection along with statistical analysis, determined tool change frequencies, resulting in maximized equipment up-time.

- Focused on system tools of 5S, value stream mapping, cellular manufacturing, level loading, kanban, standardized work, visual management, SMED, TPM, OEE, and poka yoke.

- Reduced quality and production problems by training the production support groups and associates in various problem solving methodologies - 5 Why’s, DOE, Fishbone and Cause-Effect Analysis.

- Functioned as Kaizen blitz coordinator/facilitator conducting (60) kaizen blitz’s, working on projects identified by company metrics, improving overall operational performance,

energizing/empowering the work force. Coordinated the employee involvement program, 2 ideas/month with 80% implementation.

- Completed (3) six sigma black belt projects, utilizing the DMAIC process, identified projects for black belts based on company metrics, chaired status reviews, provided mentoring (Dorian Shanin).

- Achieved TPS philosophy implementation, through regular review of deployment plan, adjusted

targets based on results of TPS site assessments, worked with divisional lean managers.

- Maintained TPS implementation momentum by conducting regular assessments, reviewing strategy, resolving deployment issues, posting metrics and communicating issues / results with management.

Engineering Manager, Coupled Products Inc., Upper Sandusky, OH 1994–2001

- Developed ‘equipment standards’ manual that was adopted division wide for the purchase of new equipment, resulting in common spare parts and control systems minimizing downtime and costs.

- Lowered operating cost by replacing equipment that couldn’t be made reliable, determined pay-back justification, wrote capital appropriation request, purchased, installed, completed start-up validation.

- Implemented set-up reduction in production areas, utilizing standardized locations, modular fixtures, 5S and SMED principles, which reduced change over times and costs by 75%.

- Achieved work standardization, creating visual work instructions and SOP’s for the manual assembly of 300+ different product configurations, eliminating errors, rework delays and costs.

Lean Manufacturing Engineer, Coupled Products Inc., Upper Sandusky, OH 1992–1994

- Site trainer for facility conducting 5S, SMED, TPM and Poka Yoke training along with various problem solving methodologies (5 Why’s, Fishbone, 5M’s), improving the overall capabilities of the work

force.

- Focused on safety, quality, production and delivery issues, by being ‘hand-on’ and working closely with production team members, providing poka yoke devices, process documentation and training.

- Increased equipment reliability, achieved OEE / FTT levels of 92% and 98% respectively, utilized preventative maintenance, statistical analysis, validation of tooling and fixtures.

- Transformed assembly area into work cells, improved product flow, modified work stations to make them ergonomically safe, achieved takt time, requirements balanced loads and lowered costs.

- Focused on eliminating quality issues, making sure the visual instructions and process controls were in place and effective, utilized poka yokes and quick change tooling, which eliminated quality issues.

EDUCATION:

Masters Business Administration Ashland University (Ashland, Ohio)

BS (Education/Engineering Technology) Bowling Green State University (Bowling Green, Ohio)

Associate (Mechanical Engineering) North Central State College (Mansfield, Ohio)

PROFESSIONAL ENHANCEMENT:

- Advanced Management (Larry Holt Assoc .- 08/2005)

- Lean Manufacturing (U of Kentucky - 01/1999)

- Advanced Lean Management (U of Kentucky - 03/2005)

- Total Productive Maintenance (Productivity Inc. - 03/1991)

- Six Sigma - Black Belt (Dana March – May 2001)

- Quick Change Over (Productivity Inc - 03/1990)

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