Manager Engineer

JERALD E. FORBES (Jerry)

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

Taylorsville, KY 40071

email: *****.******.****@*****.***

Telephone: 502-***-**** or mobile 502-***-****

Innovative Six Sigma Master Black Belt quality executive with current Lean Six Sigma global implementation skills. Background Includes years of automotive manufacturing experience leading the implementation of the latest quality improvement initiatives at Ford and Suppliers globally. Utilize the following quality tools and methodologies: Six Sigma DMAIC, Lean, Minitab, Kaizen, APQP, DFMEA, PFMEA, Control Plan, SPC, Gage R&R, GD&T, 5S, KANBAN, Poke-Yoke, Is-Is Not, DOE, Shainin, and Deming, to drive improvements. Implemented and audited quality operating systems to achieve QS9000 and ISO9002 certification at Ford Asia Greenfield Plants. Additional experiences include: product launches, supply chain, design, project engineering, production supervision, supplier site development, and manufacturing engineering management.

Approach

• Champion initiatives with a hands-on team work problem solving approach.

• Customer focused to eliminate non value added waste.

• Target the right lean projects and personnel to train and mentor to achieve fast results for organization.

• Delegate, motivate, coach and hold team members accountable for sustained objectives.

• Apply quality innovation tools as needed but always keep it simple for ease of use in the organization.

Arvato Bertelsmann Experience and Results:

Lean Manufacturing Manager, Louisville, KY 2007 to current

Lean Manufacturing Manager in the Louisville Plant and responsible for developing the Lean Six Sigma approach and deploying it globally. Developed custom Champion and Greenbelt training materials for the Arvato Digital Services packaging business. Trained and certified 88 Champions and 32 Greenbelts in 6 Plants located in Kentucky, Wisconsin, North Carolina, Singapore, Hong Kong, and Hangzhou China. Mentored and coached Plant Steering teams, Champions and Greenbelts to drive project closure of 41 projects resulting in combined annualized saving of $5,611,576. Managed the Louisville Plant industrial engineering team and successful new product launches such as Microsoft WIN7 and Apple retail store.

Ford Motor Company Experience and Results:

Supplier Quality Manager, St. Louis, MO and Louisville, KY 2004 to 2007

Supplier Quality Resident Manager for over 400 Suppliers in the Louisville and St. Louis Plants assembling the Ford Explorer, Mountaineer, Sport Trac, and Aviator vehicles. Reported to the Purchasing headquarters Truck Resident Supervisor and Plant Manager. Championed the Supplier Quality Operation System driving a 54% improvement in quality rejects at chronic suppliers. Led supplier teams using Lean Six-Sigma tools to drive permanent corrective actions. Reported monthly status to Plant Management, Purchasing and Chief Engineers. Drove the identification and resolution of 26 supplier quality warranty issues. Utilized team work to help drive the warranty repairs to the vehicle’s historical lowest level. Led the Supplier Quality launch effort for 12 new vehicle changes consisting of over 1,500 parts. Used problem solving skills with suppliers to resolve 85 issues to meet launch timing. Reported out supplier quality status in executive launch review meetings. Led supplier quality resolution to Assembly Plant Q1 endorsement, stop ship and dispute issues. Used relationship building and negotiating technique skills with facts and data to obtain agreements between Suppliers and the Assembly Plants.

Supplier Chassis Site Specialists, Dearborn, MI 2003 to 2004

Chassis Strategy Site Engineer Specialists responsible to drive quality improvement at 18 suppliers using the Ford Global Supplier Quality Improvement System. Responsible for chassis spindle assemblies, shocks, springs, and stabilizer bars. Some suppliers were Tokico, Tenneco, SACHS, NTN, Metaldyne, Hitachi Metals, Ohio Cast, and SMW. Reported to the Purchasing Supplier Quality Chassis Strategy Manager. Utilized Lean Six Sigma problem solving, mentoring and coaching skills to help 6 suppliers achieve the Q1 award. Conducted quality system site audits to improve supplier’s quality system. Conducted on-site supplier launch readiness reviews. Reviewed and approved PPAP’s leading to flawless launch results at suppliers. Mentored the China Spring site engineer to achieve seamless international supplier sourcing transfer of coil springs.

Ford Six-Sigma Master Black Belt, Material Planning &

Logistics Program Strategy Specialists, Dearborn, MI 2003 to 2003

Responsible to finish Black Belt Project and utilize Lean Six Sigma skills for forward planning of logistic optimization of vehicles to be built or exported to Asia countries. Reported to the World Headquarters Asia Pacific Material Planning & Logistic Manager. Completed Taiwan Windstar Black Belt Project improving the export vehicle quality by 70% and saved $35,500/year. Applied Lean principles to optimize logistic planning for future forward model Asia vehicle programs. Utilized Lean logistic design technique for program proposal approvals by vice presidents.

Ford Six-Sigma Black Belt, Master Black Belt, Dearborn, MI 2000 to 2003

Responsible to complete black belt projects in the Material Planning & logistic export area. Reported to the World Headquarters Asia Pacific Six Sigma Deployment Champion. Implemented 2 transactional procurement system projects to eliminate and prevent excess vehicle parts at the export logistics supplier saving $335,950/year. Implemented 4 Lean Six Sigma shipping logistics process projects to optimize the US shipping method and route for exporting Explorer, Expedition, F-150 trucks and Econoline vans to the Philippines saving $779,940/year. Utilized statistical tools to validate Delphi fuel sender warranty improvement project saving $350,000/year for the Australian Ford Falcon vehicle. Conducted Green Belt training for department.

Ford Asia Pacific Quality Specialists, Dearborn, MI 1997 to 2000

Promoted to Quality Specialists position for launching new market Vehicle Assembly Plants. Responsible for developing plans and implementing Ford quality practices into new Asian Assembly Plants. Developed and successfully launched the Quality System for the Vietnam Plant in 1997 and the Philippines Plant in September 1999. Conducted Q1, ISO and FPS audits. Coached the achievement of ISO 9002 certification in the Philippines, Malaysia, and Vietnam Plants. The Philippines Plant also was endorsed as QS9000.

Ford Supplier Quality Launch Manager, Dearborn, MI 1992 to 1997

Purchasing Supplier Technical Assistance Program Manager for the Taurus/Sable/Continental Vehicles. Championed the supplier quality for new model launches. Drove supplier quality improvements for the successful launch of the 98 Continental. Achieved a successful launch of the 1996 Taurus/Sable by driving 185 suppliers to deliver quality parts meeting project timing.

Ford Production Superintendent, Rawsonville, MI 1990 to 1992

Superintendent of Manufacturing at the Ford Rawsonville Plant. Implemented a Quality Operating System to manage the throttle body assembly business. Successfully launched the work team concept with 200 members in the alternator assembly area. Improved the labor off standard by 50 heads during the 9 months in the alternator department. Also responsible for casting machining and rotor fabrication processes.

Ford Manufacturing Engineering Manager, Bedford, IN 1989 to 1990

Advanced Manufacturing Supervisor at the Ford Bedford, Indiana Plant. Responsible for managing change for the entire new model programs from concept through launch with 9 Engineers. Launched new induction brazing process for stainless steel application. Developed a new model project tracking process keeping management informed and projects on time.

Ford Product Development Resident Engineer, Bedford, IN 1987 to 1989

Promoted to Resident Engineer at the Bedford Indiana Plant representing Electrical and Fuel Handling Design Groups. Identified and resolved design and manufacturing process conflicts for the Plant. Initiated with management consultants an intervention seminar allowing organizational team building changes to occur. Volunteered to represent Ford and the Plant as the Community Relations Committee Chairman achieving the goal of improving our image in the city of Bedford.

Ford Production Supervisor and Senior Project Engineer, Bedford, IN 1986 to 1987

Initiated and received a developmental position as a Production Supervisor in the Bedford Plant. Launched the automated fuel handling assembly department. Responsible for supervising 45 hourly employees, debugging equipment and implementing departmental tools needed to achieve the Q1 award. Increased the production rate from 4,000 to 14,000 parts per day. Manufacturing Project Engineer responsible for launching the final phase of the Rockford $1,000,000 fuel handling assembly equipment in the Bedford Plant. Developed a new and debugged an old fuel handling assembly conveyor with compressed Job 1 timing.

Ford Robotics and Automation Specialists, Bedford, IN 1983 to 1986

Promoted to Staff Advanced Manufacturing Resident Engineer at the Bedford, Indiana Plant. Implemented new technology and robotics into the Plant. Developed and implemented an ASEA robot to apply hot melt glue to washer bottle covers. Assisted the fuel handling and pressure regulator Project Engineers with advanced technology as needed.

Ford Process Quality Test Engineer, Rawsonville, MI 1978 to 1983

Manufacturing Process Engineer at the Rawsonville Michigan Plant. Responsible for electronic test and calibration equipment for carburetors and fuel injectors. Conducted DOE’s to validate design changes. Developed injector test method with University of Michigan.

Education:

B.S. Mechanical Engineering – Ohio Northern University 1978

Ford Company Training

Ford Certified Six Sigma Black Belt, Certified Six Sigma Master Black Belt, Certified in Six Sigma Leadership training, Certified Six Sigma train the trainer Green Belt – Technical, Certified Ford QS9000 internal auditor

Certified Ford Technical Education Program by VP of Global Core Engineering for the following Ford Design Institute training modules: FMEA, Process Control Methods, Global 8D, Reliability, Experimental Design, Parameter Design, Tolerance Design, Systems Engineering Fundamentals, Design Verification, Production & Process Validation, and Applied Consumer Focus.

Certified Ford Corporate Quality Development Center (Lean Manufacturing, APQP, PFMEA, DFMEA, Control Plan, 8D Problem Solving, Measurement System Analysis, Quality Operating System, Control Chart, Warranty Analysis, Gage R&R, QS9000, TS16949, PPAP, SPC, GD&T, 5S, Global supplier site assessment, Q1, Poke-Yoke)

Certified EIT by the Ohio Board of Registration of Professional Engineers Other classes: Ford Production System, Kaizen, DOE, Statistics, DMAIC, Minitab, Preventative Maintenance, Power presentations, Dale Carnegie, Salaried Supervisor institute, Hourly Supervisor institute, Robotics, Microsoft (Outlook, Power Point, Excel, Word, and Project)

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