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Manufacturing operations

United States
November 13, 2009

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*** **** ****** ***: 814-***-****

Ridgway, PA 15853 Cell: 814-***-****


Results-oriented operations and manufacturing executive with over 35 years of experience improving performance, propelling growth, and decreasing costs in industrial manufacturing and assembly organizations. Strong track record increasing profitability through exemplary strategic planning and hands-on management. Broad-based expertise includes lean manufacturing, fabrication and assembly, production scheduling, sourcing, Kaizen and Six Sigma principles, inventory/materials management, warehousing, distribution, budgeting, finance, and capital improvement. Dedicated to building and motivating cross-functional teams that consistently exceed corporate expectations.


ALPHA SINTERED METALS, Ridgway, PA June 2006 – June 2009

Manufacturer of power metal gears and structural components

Vice President, Operations

Responsible for directing and monitoring plant operations, employing 192 employees

 Trained 65 employees in Six Sigma protocols for controlling process variations, reducing scrap from 15% to 7%, with a target of 4%

 Introduced a phased 5-S program, improving overall plant productivity

 Reduced inventory by $1.5 million

 Implemented lean cells, reducing unit cost by 50%

 Led a Kaizen project to reduce powder metal molding press setup time from five hours to 30 minutes

 Led acquisition of a machining operations vendor and incorporated their operations at our facility by freeing up floor space, without any additional overhead

 Worked with management team to open powder metal factory in China

 Implemented key performance indicators to monitor direct factory and manufacturing overhead costs

STANADYNE/PEPC, Tallahassee, FL 2003 – 2006

Manufacturers of valve train components and just-in-time supplies for Chrysler and Ford

Plant Manager

Responsible for directing operations for a $60M, 200-employee manufacturing plant

 Successfully launched two new products for Volkswagen and Peugeot

 Managed re-sourcing of materials from China, Korea and India, creating an annual savings of $10.5M

 Improved unit costs by applying Six Sigma principles

 Increased efficiency by converting plant from a push to a pull system

 Reduced down time by implementing preventative maintenance programs

 Increased inventory turnover from 6 to 10

 Developed a new Continuous Improvement Manager position

 Trained core team in lean manufacturing concepts and value stream mapping techniques

 Led Kaizen and Six Sigma projects to resolve problems that occurred after inventory reductions

 Organized design of experiment studies, establishing and eliminating root causes for irregularities

JDS UNIPHASE, West Trenton, NJ 2001 – 2003

Manufacturer of fiber optics components

Materials Manager

Responsible for oversight of materials department, including planning, strategic sourcing, receiving, raw material stock room, and shipping

 Reorganized the Materials department and established challenge procedures, resulting in a 90% reduction of transaction errors

 Initiated cycle-counting procedures to reduce on-hand inventory, improving inventory accuracy from 70% to over 95% and financial accuracy to over 99%

 Reduced work in progress and manufacturing cycle time by 50% by eliminating unnecessary inspections and using priority sequencing, level scheduling, pre-seal testing and validating data

 Increased inventory turnover

 Implemented consignment inventory replenishment protocol with a one-week cycle time

 Introduced monthly operations plan based on APICS sales and operations model for evaluating material and resources requirements

 Conducted employee training for an APICS Production and Inventory Management certification

MINI CIRCUITS, Brooklyn, NY 1993 – 2001

Manufacturer of radio frequency, intermediate frequency, and microwave components

Materials Manager (1997 – 2001)

 Responsible for oversight of materials department, including planning, strategic sourcing, receiving, raw material stock room, and shipping Implemented a bar-coding system for receiving transactions

 Worked with engineers to standardize parts and increase tolerance of non-critical parameters, reducing costs from 30% to 10%

 Developed strategic relationships and arranged design of experiments with new suppliers by using a supplier qualification and rating system, reducing costs by 10-15%

 Worked with suppliers and quality assurance teams to implement dock-to-stock program and eliminate incoming inspections for qualified suppliers

 Established a standardized inventory and a work-in-progress reporting system for ten subcontractors, enabling the monitoring of shrinkage

Documentation and Data Manager (1993 – 1997)

Responsible for oversight of information technology projects

 Generated successful documentation system for ISO-9001 certification

 Managed the engineering change notice system, reducing the change notice implementation time from three weeks to two working days

 Improved the data accuracy rate of bill of material to 95% by establishing custom reports to manage procurement and implementing material requirements planning

 Managed printed circuit board and prototype teams, reducing lead-time from three weeks to three working days


INDIAN NAVY (1972 – 1993)

Positions held include: Rank of Commander, Deputy Director of Naval Air Materials at Naval Headquarters, Officer-In-Charge of an Aircraft Maintenance and Repair Facility, Staff appointments in Command Headquarters, Engineer in Naval Anti-Submarine Aviation Squadrons and Naval Ships, and Assistant Naval Attaché at the Indian Embassy in Moscow


Bachelor of Science, Mechanical Engineering, 1972

Sri Venkateswara University, Tirupati, India

Additional training:

Courses in Marine Engineering at Naval College of Engineering, Lonavala, India (1974) and Aeronautical Engineering at Air Force Technical College, Bangalore, India (1976)

Achieved CPIM certification from APICS USA (2003)

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