Manufacturing Manager

KOSHY MATTHEWS

** ********* *** **.

Calgary. Alberta

Cell: +403-***-****

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

KEY SKILLS

• Six Sigma Lean Mfg / Design. Value Stream Mapping.

• Establishing Processes, Cost and C/T Indices

• MTBA/MTBF/MTTA/MTTR

• Manufacturing Excellence Production and Equipment/Engineering Operations

• Quality Systems

• Total Quality Management (TQM)

• FMEA/FAE/8D/4D

• Inventory Turns Management (ITM)

• NPI/NPPD

• Lean Manufacturing.

• Supply Chain Operations.

• TPM/TPPM

• KPI`s/Cost Breakeven Models (CBM)

• P&L

• Project Management

• Customer Strategies

• CGMP Programs/Business Development

• RCA/APQP/DMAIC

• Managing Unionized Employees & Diverse Cultures

• Statistical Process Control (SPC Level 5)/(DOE)

MANAGEMENT CAPABILITIES

Planning / Budgeting / Manufacturing.

Developed & implemented measurement matrices & plant KPI goals.

Determine manufacturing priorities in a fast pace and dynamic environment.

Overall accountability of process developments, coaching, training and mentoring sub-ordinates.

Aligning site objectives to company KPI`s and setting priorities.

Defined budget and direction based on TAM demand

Established strategic & analytical decisions for operational fluency at customer sites.

Planned equipment parameter optimization and load structures to attain OEE standards.

Product Risk assessment and adherence to quality standards internally and externally.

Overall P&L responsibility. USD$ 15 million dollars and above.

Set-up and execute new leadership/directive requirements for manufacturing/engineering teams.

Submitted proposals to senior management for approval on cost reduction and delivery deliverables.

Reported and measuring multiple plan indices, ex: SPC (Level 5), CBM, C/T, APQP etc.

Extension of process control improvement programs for multiple product lines meeting yield targets.

Introduction of Total Quality Management, CTQ`s concepts, monitoring quality issues, both internal and external identifying and implementing corrective action processes and countermeasures

Project Management / Factory Operations Management

Ensuring customer CTQ`s and standards/Customer Interface on CAR/Yields and all technical issues.

Ensure production targets stay on budget by tracking appropriate break even cost models

Compliance with statutory / safety and environmental standard requirements

Proven ability in improving reliability of operations through practical use of Continuous Improvement tools and process improvement methodologies

Administer H&S program which directed all legislative requirements as a company priority

Lead, recruited, developed, coached, motivated, counseled and appraised the performance of team members to succeed in strategic company goals

Establishing manufacturing/engineering processes, project deliverables and product development roadmaps.

Execution of projects such as SPC, Lean Manufacturing, RCA, Six Sigma and material flow strategies.

Execution of tasks independently with high level of confidentiality and commitments.

Strong independent attributes, to execute and flex decisions dealing with sub-con facilities

K. Matthews – Resume Continued

EXPERIENCE

June 2009 – Current

Sr. Product Development Manager. (Consultancy Assignment)

• Development of new products and processes aligned to customer specifics.

• Alignment and execution of strategic objectives for new application development and proliferation of existing applications to different regions/accounts

• Implement FMEA, APQP, SPC programs for product qualification and NPI design rules.

• Establish characterization studies and engineering FA process for standards and qualification of product line to market.

• Design and development of a clean room in Edmonton (developed the photolithographic process) and Calgary.

• Designed a breakthrough hall-effect sensor module for Baker and Hughes

• Set-up of quality systems and SOP for maintenance and manufacturing

• Successfully converted four (4) prototype-builds from cradle to grave.

• Designed production flows and process for volume manufacturing

• Implementation of RCA, BKM program deliverables for existing and new customers

January 2009 to June 2009: Operations/Lean Manufacturing Manager (Consultancy Assignment)

• Implemented plant wide six sigma/lean manufacturing process.

• Improved C/T by 2 days for overall manufacturing process.

• Improved documentation system and process for quality attainment.

• Reduction of service calls by 40% after implementation of lean manufacturing process.

• Parts and inventory reduction by 12% overall attaining cost breaks of CDN$62,800/monthly

June 2008 to December 2008: Maintenance/Engineering Manager (Consultancy Assignment)

• Manage maintenance operations to achieve production schedules, cost deliverables, quality standards, customer uptime, customer requirements and organizational goals.

• Achieved cost break in parts usage for overall operations by CDN$ 285,000 savings.

• Implemented maintenance programs measuring MTBA,MTBF,MTTA,MTTR attaining overall equipment efficiency gains to 78%

• Managed three site operations in Alberta(Ft Mc Murray, Edmonton, Grand Prairie)

• Implemented downtime program for equipment hours measurement for cost/k utilization hours

• Technical training manuals written and done for internal technical staff.

August 2005 – February 2008: Director Manufacturing/Engineering Operations, ATTOGENIX BIOSYSTEMS LTD.

• Manage manufacturing plant operations to achieve production schedules, cost deliverables, quality standards, manufacturing plant yields, customer requirements and organizational goals

• Leading the strategic supply chain operations and out sourcing of vendors and auditing quality systems to meet the needs of the products manufactured

• Oversee cradle to grave new product design, development & improvements of bio-medical chips

• Analytical studies on fluid dynamics, composite materials, engineering plastics and structural design on new products.

• Set up manufacturing matrices, Strategic Business Plan, installed Lean Manufacturing and Six Sigma cost initiative programs for overall manufacturing operations for the plant

• Established a robust wet etch process for chip production, implementing SPC, FMEA and APQP programs.

• Interface with customers on presales technical needs and execute customer production requirements.

• Completed development of bio-medical disease detection chips reducing unit cost by 30%.Savings of USD$ 1.50 per unit

• Implemented medical regulatory requirements FDA 21 CFR 820.30

• Filing a medical device patent under the company banner- In process.

2005 – 2006: Manufacturing Operations Director, STATSCHIPPAC LTD. – Singapore (Consultancy Assignment). Set-up and Managed 4 operation sites-(China, Malaysia, South Korea and Singapore)

• Provided leadership, established analytical engineering yield improvement programs, enhanced equipment and implemented a cost control / inventory turns program emphasizing productivity & lower costs for multiple sites across Asia.

• Implemented Green-Line Process Indices for Motorola (customer) achieving yield goals of 99.97%

• Set-up a comprehensive engineering and manufacturing measurement matrix.

• Developed and launched new products from inception to manufacturing release at selected sites.

• Trained personnel regarding design rules, new technologies, lean manufacturing, 5S, FIFO and process management

• Established strategic plans for continuous yield improvement programs, manufacturing productivity and cost per K standards for tooling and equipment parts usage in the Maintenance Department

• Introduced a plant-wide Lean Manufacturing Six Sigma Program – achieved a 30% productivity improvement and increased sales revenue by USD$6.4 million per annum

• Won the Silver Recognition Award for the introduction of Lean Manufacturing / CCB / MRB / Yield Management programs across multiple company facilities in Asia

• Commissioned equipment, training, process and manufacturing indices for the wafer bumping operation and implemented successful TPPM and TQM programs

2002 – 2005: Director Manufacturing Operations- INNOVATIVE MICRO PACKAGING SYSTEMS INC. – South Korea.

• Commissioned a wafer fabrication manufacturing facility - multi-tasked to develop manufacturing systems, an effective operational strategy, COGS attainment, efficient yield processes and a strategic business plan

• Set up process parameters and standard operating procedures (SOP’S, AQS, MS, APQP, FMEA), vendor qualification indices and matrix

• Managed design for Six Sigma / DMAIC and RCA for R&D and the Engineering Department

• Introduced Lean Mfg Practices with emphasis on AOTD, C/T, ITurns, UPH / Line Attainment matrix

• Implemented Autonomous Maintenance / TPPM, tool life monitoring and 5S programs for maintenance

• Introduced Cost/K standards, P&L and Breakeven Models to increase revenue

• Created personnel development program including a review system and resource planning

• Global sourcing matrix initiated for cost breakevens.

• Developed New Product. (Fluidic Based Devices) Implementation procedures and methodologies and selected OEM sites across Asia, working with wafer manufacturing houses locally and in India establishing process and recommendations for yield improvements

• Established process and quality parameters to attain QS 9000/ISO 13485/ISO 14000 certification

K. Matthews – Resume Continued

EXPERIENCE

2000 – 2002: ADVANCE INNOVATIVE TECH – Singapore.

Sr. Mgr Engineering and R&D,

1997 – 2000: PT. OMEDATA ELECTRONICS – Indonesia

Engineering Manager. Promoted to Operations Director for Manufacturing & Product Engineering

1991 – 1996: AGERE SYSTEMS (Formerly AT&T MICROELECTRONICS) – Singapore/USA

Senior Packaging Development Engineer

1987 – 1991: National Semiconductor Electronics – Malaysia/USA

Maintenance Engineer

EDUCATION

• Bachelors of Science (Honours) – Physics

KERALA STATE UNIVERSITY – India

• Diploma Mechanical Engineering

FEDERAL INSTITUTE OF TECHNOLOGY - Malaysia

TRAINING

• Sputtering, Etching, UV and Mask Aligners Ngee Ann Polytechnic

• Encapsulation and Packaging Designs for Semiconductor Industries, Singapore Polytechnic

• Program Management Skills & Workshop, Development Dimensions International

• Problem Solving and Decision Making, Kepnor Tregor

• Auto-Cad 2000 Advance Level, Computer Training Centre

• Ansys Simulation Design Software, AT&T Microelectronics (In-house)

• MEMS-CAD Design, Future Techno Design

• MATH LAB (Self-trained)

• Promise/ERP and SAP Manufacturing Workflow Applications Systems

• DMAIC

AFFILIATIONS

Institute of Project Management Canada (PMI)

Institute of Electrical & Electronics Engineers (IEEE)

Semiconductor Manufacturing Excellence USA (SME)

Institute of Micro-Electronics Advance Packaging USA (IMAPS)

Institute of Physics London United Kingdom (IOP)

REFERENCES

Available upon request

Contact this candidate