Operations/Quality Executive
Resume:
JAMES E. CHLEBEK
Spring Grove, IL
*******@***.***
QUALIFICATION SUMMARY
• Expert in the identification, analysis, and resolution of diverse operational issues, continuously maintaining top performance. A quality/manufacturing professional with a twenty plus year record of accomplishments in operations, quality assurance, sourcing/supply chain, manufacturing, and general management, with emphasis in electronics, plastics, equipment and metal processing. P/L responsibilities. Solid background in program/project management and hands-on training at all levels of the company. Including leading trainers at multiple sites and facilities.
• Operational management includes oversight of multiple manufacturing plants, quality, business development, sales, customer relations, and vendor negotiations and contracts. Foresight in developing systems that track and respond to the needs relevant to accelerating operational performance for international and domestic manufacturing, sourcing and logistics. Proven ability to design and implement new processes, including but not limited to: COPQ, TQM, and Lean Six Sigma in both automotive and consumer applications. Experienced in the implementation of the ISO/QS/FDA standards in multiple locations and dealing with medical device directives.
• Recognized for outstanding leadership and problem solving abilities; innate ability to analyze team members and create innovative methods to motivate them to higher levels of performance / productivity. Proven track record in improving productivity, reducing costs, and increasing quality and reliability enhancing sales growth and customer satisfaction. Integral part in the planning, development, implementation and evaluation of strategic business and performance goals. ERP systems experience using Oracle and strong international background including Canada, Mexico, Europe and Asia.
PROFESSIONAL EXPERIENCE
Illinois Roof Consulting Assoc., McHenry Illinois March 2009 to Present
Director field Quality
Responsible for the Quality compliance inspection during roof construction. As well as assuring that the quality and quantity of materials and installation are as agreed in the contract. Provides a link for daily communications between the owner, the contractor, the building occupant and the project manager. Examines and records conditions and incidents that affect the conduct of the project. Provides observations and experience assist the owner and the project manager to evaluate the progress of the job.
Accomplishments:
• Introduced Lean practices into the specification preparation process
• Assisted in the streamlining of the project manual which contains systemic specifications along with site-use and administrative requirements. Assuring complete documents eliminate misunderstandings which lead to cost overruns.
Perfect Plastic Printing, St. Charles IL April 2005 to May 2008
Executive Director/Vice President of Quality and Product Development
Responsible for elevating the quality and product development systems to meet customer and industry needs. Develop and implement a Lean/Six Sigma program that includes DFSS including the training of greenbelts and plant associates. Identify areas of weakness in the system and implement necessary improvements. Develop and execute strategic, sales and operational plans. Lead the implementation of supply chain strategy that significantly reduced waste and improved EBITDA. Established key metrics to track business and operational results. Accountable for sourcing requirements and contracts.
Accomplishments:
• Instituted a new formal Product Development Process
• Established and lead Lean/Six Sigma Teams to attack waste and process variation.
• Building relationships and establishing supply chain requirements with off-shore suppliers
• Introduce new technologies into the industry
• Facilitated decision-making processes and eliminated $500,000 in annual costs by reorganizing the operational flow through Lean techniques
• Provided leadership in developing and implementing organizational objectives and policies, Key Process Indicators, and other quality measures
Pride Mobility, Exeter PA October 2004 to April 2005
Vice President of Quality and Product Integrity
Responsible for the establishment of strategic quality, and reliability initiatives on a global basis. Develop and execute strategic and operational quality business plans that incorporate manufacturing operations, logistics, and product development and supply chain development on a global basis. Negotiate sourcing issues and establish supply chain requirements.
Pride Mobility – VP of Quality & Product Integrity Con’t.
Accomplishments:
• Chairman of Product Safety Committee – Management representative to FDA
• Establish formal New Product Development Process
• Implemented formal accelerated testing and reliability programs
• Lead efforts in FTQ (First Time Quality) reductions to improve overall customer experience and operational efficiencies
• Establish formal off-shore supplier controls
• Introduced continuous improvement and lean principals to better support operational objectives and customer requirements through a fully integrated training program that included off shore sources.
• Established procurement strategies for international sources.
Life Fitness, Franklin Park, Illinois - a 500M Brunswick Company September 1998 to October 2004
Sr. Director, Global Quality and Product Integrity
Responsible for the development and execution of strategic and operational quality business plans that incorporate manufacturing operations, logistics, training, product development and supply chain involvement on a global basis involving four manufacturing facilities of consumer products. P&L responsibility for capital budgets up to $10 million.
Accomplishments:
• Chairman of the Product Performance Committee
• Challenged to introduce new quality systems ISO 9000, Lean Six Sigma, COPQ, accelerated testing, product introductions and process operations in multiple facility environments. Demonstrated success with fast paced, entrepreneurial and customer driven organization.
• Delivered a reduction in material defects from 4.5% to less than 1.8%, resulting in reduced downtime, and increasing revenues by more than $1MM
• Reduced warranty exposure by over $6MM in one year and $9MM over three years.
• Improved on-time delivery and reduced logistics costs through Lean principles.
• Directed the formalization of a Supplier Quality Program.
• Directed the formalization of a Warranty Tracking System to address customer/product issues.
• Assisted in the management of Customer Service and Manufacturing Engineering.
Werner Company, Franklin Park, Illinois October 1992 to September 1998
Senior Manager, Quality Assurance and Fiberglass Product Development
Responsible for implementation of ISO/QS 9000 Quality System and development of fiberglass processes for the corporation’s three manufacturing facilities. Full accountability for planning, staffing, technology, assets and management of development activities for fiberglass products and quality assurance.
Accomplishments:
• Orchestrated an aggressive reengineering of the fiberglass development activities, reducing costs, streamlining production and improving profitability.
• Reduced manufacturing cycle times (increased fiberglass rail production by 70% to 100%), reducing costs by more than 40%.
• Developed capital plan and rationalized assembly processes through the use of Six Sigma techniques and reduced annual operating expenses by more than $4MM.
• Restructured the entire corporations quality systems including the implementation of continuous improvement programs, strategic supply distribution planning and supplier selection/qualification.
• Maintained overall responsibility of budgeting, project management, cost justifications for engineering and quality activities. Also accountable for estimating and scheduling of engineering, labor and capital required to meet completion dates, production requirements and management objectives.
L. R. Nelson Corporation, Peoria, Illinois April 1987 to October 1992
Sr. Technical Manager Quality Assurance
Responsible for the management of electronic development engineering, manufacturing process engineering, quality engineering and tool engineering. Duties included the establishment of new product process requirements for electronics, plastics and metals applications.
Accomplishments:
• Managed all overseas manufacturing and product design including supply chain.
• Led a cross functional team in the redesign of electronic controllers manufactured overseas resulting in cost savings of more than 20%.
• Revamped and managed a tooling program that saved more than $500,000 in annual tool maintenance costs.
• Aggressively formulated improvements in the management, conduction and assistance of research and development for various processes, tooling and electronic design/projects.
• Introduced SPC and Lean techniques in manufacturing that reduced operational costs by more than 15%.
EDUCATION
Masters Degree in Operations and Technology Management, 1999
Illinois Institute of Technology Stuart Graduate School of Business, Chicago, Illinois
Bachelor of Science in Electrical Engineering Technology, 1978
DeVry Institute of Technology, Chicago, Illinois
Trained facilitator of Kepner / Trego Problem Solving and Decision Analysis
Trained in Lean Six Sigma – Black Belt
ASQ Certified Quality Engineer, Quality Auditor
ISO 9000 Lead Assessor
References - furnished upon request.
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