Re: Quality Manager

SUMMARY

Master degreed Mechanical Engineer with five years manufacturing experience, including two years in management. Expertise in Engineering, Continuous Improvement, Lean Manufacturing, Quality Assurance and Productivity projects using tools such as FMEA, Corrective Action (8D), Kaizen, SMED, VSM, Kanban, TPM, Supplier-Process quality and Six Sigma/SPC. DMAIC Six-Sigma Black Belt certified. Delivered over $2 million annualized savings from productivity projects.

PROFESSIONAL EXPERIENCE

Newell Rubbermaid - Office Products Manufacturing/Distribution Plant, Lewisburg, TN 2005-Present

350-employee, $80 million manufacturer of writing instruments

Quality Assurance Manager

• Conducted Six Sigma DOE studies to qualify 178 SKUs of pencil lacquer in lieu of hazardous chemical compliance legislation for children’s products. Project mitigated $1.2 million cost risk and is on track to generate $200,000 in usage optimization from key DOE learnings.

• Maintained a customer/consumer complaints database and generated corrective actions that reduced complaints by 22% in 2007.

• Implemented APQP/Vendor Certification process for 233 suppliers to track material changes and optimize charge backs that resulted in an 85% reduction of QA hold inventory.

• Reduced cost of quality by 50% via process scrap reduction, and optimization of SAP transactional functions for Production Storage Areas and material movement.

• Managed inventory accuracy and cycle counting for strategic raw material, work-in-process and finished goods.

• Created a supplier ratings database and identified development opportunities for ten suppliers.

• Generated $60,000 cost avoidance via material standardization and specification evaluations.

• Delivered $80,000 savings in scrap reduction projects.

• Standardized visual quality systems to eliminate operator bias.

• Managed the quality control gate for new product launches including packaging/product design changes, incoming quality processes, pilot runs and first article approvals.

• Manage eight direct reports.

• Mentor for engineers pursuing Six Sigma Green Belt training and certification.

• Plant representative on Global Business Team for Hi-Tech Business Unit.

• Certified in Newell Rubbermaid’s Operational Excellence Training.

Manufacturing Engineer

• Managed the facilities department including compressed air systems, HVAC, water treatment and construction projects.

• Completed labor and overhead productivity projects with $830,000 annualized savings involving $600,000 capital investment.

o Automated label stock lines to reduce 20,000 labor hours across 86 SKUs resulting in annualized labor savings of $450,000 with a capital investment of $400,000.

o Collaborated with Supply Chain and marketing groups to drive SKU consolidation and supplier quality agreements resulting in $50,000 annualized savings.

o Conducted a Six-Sigma project to reduce energy usage by 17% via optimization of lighting, compressed air, HVAC and shut-downs resulting in annualized savings of $160,000 and a cost avoidance of $150,000.

o Provided energy consultation to other Sanford facilities in North America to generate $1 million productivity opportunity.

• Led training and deployment of Overall Equipment Efficiency (“OEE”) metric, 5-S, Visual Factory and Total Productive Maintenance (TPM).

• Certified in Newell Rubbermaid’s “Project Management in a Business Environment.”

Continuous Improvement (CI) Engineer

• Eliminated 12,000 labor hours via a kaizen event and KanBan implementation for packaging efficiency improvements resulting in a $200,000 annualized labor and overhead savings.

• Conducted SMED projects to reduce changeovers by over 50%. Related improvements resulted in annualized labor and material savings of $58,000.

• Project Engineer for pen-point fabrication operations relocation to Low Cost Country.

Trane Corp. Manufacturing Plant, Clarksville, TN 2003-2004

1500-employee, $400 million manufacturer of HVAC systems

Manufacturing Co-op Engineer

• Conducted a process capability study to evaluate ergonomics of a fastener assembly operation.

• Performed computer simulations to evaluate the stresses on fasteners and support units that resulted in elimination of 2% non-value-added fasteners in assembly components.

• Conducted time studies for equipment specifications and performance benchmarking for roll formers, panel benders, turnkey polyurethane foam systems and NC punch machines.

Center for Electric Power, Cookeville, TN 2001-2003

Research Assistant

• Evaluated the hydrodynamic performance and removal efficiency of a storm water separator for Aquashield Inc. (Hixon, TN).

EDUCATION

Tennessee Technological University, Cookeville, TN

Master of Science, Mechanical Engineering, 2004, GPA 4.0/4.0

Jawaharlal Nehru Technological University, Hyderabad, India

Bachelor of Technology, Mechanical Engineering (Mechatronics), 2001, GPA 3.8/4.0

TRAINING

Newell Six Sigma Black Belt Program (Six Sigma Associates)

DMAIC Six-Sigma Training (Sanford L.P. – Lewisburg)

Value Stream Mapping (University of Tennessee)

Introduction to Project Management for Processes (University of Tennessee)

Energy Workshop (Mort Energy/Summit Energy)

Compressed Air System Energy Reduction Workshop (Tennessee Energy Division)

COMPUTER SKILLS

Minitab 14; JMP 6.0; QMF for Windows; MATLAB 6.1; AutoCAD 2000;

“C;” FORTRAN; MS-Office, MS Project, EVSM. ERP Systems: SAP, ASI

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