Manager Six Sigma

WESLEY W. HACKNEY

910-***-****(Wk-cell) *** Edinboro Dr. Southern Pines, NC 28387 910-***-****(Hm) Email:**********@*****.***

OBJECTIVE

A critical leadership role as a change agent with an organization utilizing my extensive hands-on experience in manufacturing to grow the bottom line and compete in the current economy through the use of Lean Sigma principles.

PROFESSIONAL EXPERIENCE

ARGO Inc, Chicago, IL November 2009 – Present Senior Lean Consultant – Working in US, Canada, and Europe with a variety of companies ranging from, railroad, plastics, electronics, medical devices, and corrugated cardboard analyzing and implementing lean and six sigma cultures to reduce costs and improve productivity. Served as a mentor to other consultants in learning how to implement lean.

Accomplishments

• Achieved 25% reduction in turnaround time for railcars (30 to 24 hours) for one railroad company in a period of 8 months improving the on-time rate from 30% to 90% while working with a union organization.

• Worked with electronics company to reduce inventory from $5M to $3.5M (30% reduction) implemented over a period of 3 months.

• Led kaizen events with plastics extruding and converting company to improve machine uptime by 10% over a period of 2 months resulting in an additional projected annual sales of $3.6M

• Successfully worked with a team of other consultants to develop a master plan to implement a six sigma project schedule for a European corrugated cardboard company encompassing 20 facilities.

ARVINMERITOR, Maxton, NC August 2007 – October 2009 Plant Lean Expert – Served as lead person to implement Lean manufacturing principles from the ground up as a part of a company wide initiative. The Maxton facility manufactures Military and Commercial Axles, Transfer Cases and Drive Shafts with records sales in 2009 of $450M. Primary responsibility was to lead the plant in development and implementation of an overall long term lean strategy in keeping with the TPS principles.

Reason For Leaving: Part of companywide reduction in force of 10% during peak of US recession.

Accomplishments

• Achieved an overall plantwide productivity improvement of 25% over 2 years from 36.1% to 62.2% .

• Reduced inventory from $22K to $11K and increased inventory turns from 12 to 19.5 by implementing a plant wide Kanban system for all small parts kitting operations and eliminated 50% of bulk materials stored in the central warehouse by converting to line side staging at each production line.

• Developed a master plan to implement 5S process including self directed 5S team in each production area.

• Led plant in development of preassembly kitting process saving $240K in annual labor savings.

• Led a lean transformation of Drive Shaft area resulting in improving productivity 19 6% to 39.1% in 15 months.

GUILFORD, Greensboro, NC August 2006 – August 2007 Lean \ Six Sigma Consultant – Worked in a one year consulting role reporting to the General Manager of Lean & Six Sigma to train management and staff and develop a strategy to implementing continuous improvement process for 5 plant in the southeast US. The company’s primary business was manufacturing and lamination of fabric for automotive interiors.

Reason For Leaving: Pursue full-time vs contract position

Accomplishments

• Assisted in developing training program for implementing Lean manufacturing and trained management and selected individuals at each operation in 5S, Value Stream Mapping, and basic lean concepts.

• Worked with 2 other Blackbelts to train and mentor 10 individuals at each of the 5 facilities in Six Sigma.

• All Greenbelt projects resulted in a minimum 50% defect reduction with an average savings of $50K per project.

• Lean activities focused on inventory reduction resulted in a WIP reduction of 20% ($250K)..

SIMONDS INTERNATIONAL, Florence, SC August 2004 – August 2007 Lean Coordinator – Peer level with Plant Manager with accountability to VP of Manufacturing. Company wide effort to implement Lean using TPS principles for 5 facilities fabricating steel into knives and saws for wood and industrial cutting applications. Developed implementation plan then trained, mentored, and led Kaizen activities with all plant personnel.

Reason For Leaving: Florence plant closed which would required me to relocate to New England facility.

Accomplishments

• Successfully converted 7 product families from batch to cellular manufacturing reducing thru put time 60-80%, WIP inventory 50% and created over 20K sq. ft. of floor space.

• Established Kanban inventory pull systems for 4 product families reducing finished goods inventory $1M and reduced finished goods inventory storage 50% in shipping warehouse.

• Worked with Maintenance Manager to start plant TPM program and introduced to shop floor.

• Introduced visual metric boards in all facilities to track daily/weekly performance & established daily walk thru.

DANAHER CONTROLS, Elizabethtown, NC July 1999 – August 2004

Lean Sigma/Business Unit Manager - Hired as QA/DBS (Danaher Business Systems) Manager reporting to VP of

Operations for plant manufacturing mechanical and electronic counters/controllers ($60M sales). Plant operation was based on Toyota Production System (TPS) manufacturing methods. Led introduction of Six Sigma to the company’s overall lean management philosophy and skill sets known as DBS. Coordinator for all monthly Kaizen activities and continuous improvement projects. Added responsibility in 6/03 as Business Unit Manager for two product groups with sales of $11M.

Reason For Leaving: Pursue career opportunity to assist company in implementing Lean/Sigma from ground up.

Accomplishments:

• Achieved 50% reduction in plant warranty returns 2000 to 2004.

• Kaizen project activities have yielded over 15% to 18% improvement in productivity cost annually.

• Coordinated implementation of inventory reduction Kaizen’s which reduced inventory from $5.4M to $2.8M .

• Corporate wide instructor\mentor for Lean\Sigma and conducted training & Kaizen events at other plants.

• Part of two teams to transfer new product groups into plant. Partlow-West in 2000 and Thomson Industries in 2003. Each move involved converting the operations from batch to cellular manufacturing.

GENERAL ELECTRIC, Dothan, AL June 1996 – July 1999

Lead Blackbelt/Master Blackbelt – Began as Lead Blackbelt for DC Motor Plant focusing on use of Six Sigma and Lean skills to reduce manufacturing costs in all areas of the facility ranging from production scrap/rework, process cycle time, to inventory reduction. Completed GE’s Master Blackbelt training and served as Master Blackbelt in 98/99. Reason For Leaving: Career path offered by GE would require moving my family every 18 months.

Accomplishments:

• Personally responsible for projects resulting in over $500K annual savings in 1997 & 1998

• Established plant wide system to track production scrap resulting in projects saving $350K in internal scrap.

• Trained and mentored salaried and hourly personnel in use of Six Sigma and Lean tools.

• Assisted in hiring and training 2 Blackbelts for Dothan.

• Worked with plant to exceed policy deployment savings goals of $1.4 M (1997), $1.7 M (1998), $1.5M (1999)

ALLIED SIGNAL, Greenville, AL January 1995 – June 1996

Blackbelt - Responsible for coordination of process improvement, defect reduction, and lean manufacturing projects for Airbag and Seatbelt Assembly operations in Greenville and Knoxville in addition to Juarez and Aqua Puerta, Mexico.

Reason For Leaving: Greenville plant closing and relocating to Juarez, Mexico and I would be relocated to El Paso.

Accomplishments:

• Obtained Six Sigma Blackbelt Certification including Certificate Of Merit Award For “MOST TENACIOUS”.

• Led projects contributing to reducing 1995 Plant COPQ $1.9 M, a 26% improvement over 1994.

• Achieved a minimum of 75% reduction/improvement on all individual projects completed.

• Conducted Greenbelt training for salaried and key hourly associates.

AKZO NOBEL FIBERS INC., Scottsboro, AL 1992 - 1995

QA Manager - Responsible for quality systems in a polyester and nylon fibers facility. Managed staff responsible for testing, customer service and vendor quality. Trained in Europe on ISO-9000 standards and led successful completion of plant ISO-9000 certification. Liaison for alternative polyester chip supplier in Mexico resulting in $1.5M savings per year. Worked with engineering on process variation reduction projects resulting in eliminating QA testing by 50%.

Reason For Leaving: Pursue career advancement and attain Blackbelt and Lean Manufacturing Certifications

FUJI FILM INC., Greenwood, SC 1988 -1992

Quality Assurance Engineer - Trained 4 months in Japan learning production operations, quality systems, and team problem solving. Served as special troubleshooter for suppliers not meeting standards

Reason For Leaving: Replacement of salaried American workforce.

ENGELHARD CORPORATION, Seneca, SC 1986 - 1988

Process Improvement Engineer - Responsible for coordinating relocation of QC functions from unionized facility in Newark, NJ to new chemical catalyst plant in SC. Developed and introduced process improvement program to production

BASF CORPORATION, Freeport, TX 1984 - 1986

Lab Manager/Production Chemist - Managed process control labs for six Acrylic Monomer Plants.

EDUCATION

UNIVERSITY OF TEXAS AT DALLAS, Richardson, TX December 1983

MS Degree; Environmental Sciences

Maintained 3.7/4.0 GPA while working full time as a chemist at Lone Star Gas Co., Dallas, TX

NORTH TEXAS STATE UNIVERSITY, Denton, TX December 1978

BS Degree; Chemistry (Minor:Math)

REFERENCES AVALIABLE UPON REQUEST

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