Dynamic leader and change agent for continuous improvement and quality assurance with 10+ years' of professional experience. Proven results in exceeding targets while improving efficiency and reducing costs through metrics. Demonstrated skills in creating, leading and executing process improvements. Certified Lean Six Sigma Black Belt (LSSBB) with excellent knowledge and experience with lean tools such as 5S, Kaizen, Value Stream Mapping, Visual workplace, Set-up reduction; strong knowledge of advanced statistical analysis, including Design of Experiments (DOE). ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE) with extensive experience in ISO auditing and compliance, developing and maintaining effective quality management systems. Ability to build quality by using Six Sigma as a disciplined data driven approach for eliminating defects. Strong interpersonal skills, excellent communication skills, ability to supervise, mentor others and a good team player. Self-Starter with a high level of discipline and motivation.
Quality & Lean Six Sigma Manager10/2013 to CurrentIFS Coatings IncGainesville, TX
IFS Coatings is a manufacturer of powder coatings for architectural, appliance, industrial, retail and other applications.
Champion process improvement and operational excellence projects with a focus on cost savings and improving efficiencies.
Reduced 25% of manufacturing scrap by identifying the major source in the process and provided solution to rework scrap effectively while reducing the company's environmental footprint.
Achieved significant energy savings for the company by implementing energy smart solutions in all areas of the company, resulting in 15% energy bill savings.
Improved company's turnaround time with new coating colors by 50% with a new improved process flow while reducing the cost of the product by 5% through optimizing quantity of pigments used.
Automated data collection of all machine's important performance data through PLC and established a successful predictive maintenance program based on the data.
Initiated the need for the company's expansion of QC and R&D lab and executed the project from concept to completion.
This improved company's testing abilities and attracted new business while reducing overall customer returns by 45%.
Used value stream mapping to map the flow of product in the manufacturing process and streamlined the flow by redesigning plant layout with Point of Use Storage (POUS).
Automated finished good packaging process with auto fill and label, eliminating the filling and labelling errors caused by manual operation.
Created a new process for effective communication of critical customer product requirements from the R&D lab to manufacturing and QC testing.
Conducted Kaizen events with different teams across the company including R&D, Customer Service, IT, Production and Shipping.
Develop and deliver lean six sigma training programs across the organization, conducted 5S training workshops in various areas of the plant, resulting in positive transformation work environment and reduced waste.
Work with Executive Management to design quality development strategy for the two primary sites in Gainesville TX and Ardmore OK, and helped company acquire new market areas such as architectural and appliance markets by satisfying customer specific quality system requirements.
Key liaison for customer complaints and corrective actions, improved response time to customer complaints while improving the documentation on the corrective action report.
Quality Manager & Lean Six Sigma Black Belt05/2011 to 10/2013Sherman, TX
Presco is a manufacturer of commercial marking products and customized vinyl film.
Led projects that focused on defect reduction to achieve cost reduction, productivity improvements, process efficiency improvements, yield improvements, uptime improvements and quality improvements for both plants of the company.
Reduced customer returns and internal scrap by 50% in the stake flag product line and implemented procedures in place to sustain the improvements.
Performed a kano analysis on the company's roll flagging products and identified the non-value add product offerings and eliminated them by consolidating products to save company's manufacturing cost and inventory carrying costs.
Performed value stream analysis on the product flow of the manufacturing process, and implemented a new QC check value add step upstream that reduced scrap by 25% and increased machine uptime by 12%.
Reduced the manufacturing change over time in roller set up by 50% by taking the team through a four step rapid set up process.
Improved the process of onboarding a new customer by using value stream mapping , this helped the company onboard one of their biggest new customer smoothly whose business increased the volume of stake flag business by 50%.
Conducted Lean training including 5S workshops throughout the company and created a lean culture for all employees across the organization.
Implemented Good Manufacturing Practices (GMP) in company's tool management program that resulted in cost savings by reducing the annual tooling budget by 25% and extended the tooling life.
Designed and implemented company's quality management system and helped the company acquire a big new customer in the medical device market.
Created a new Corrective Action Preventive Action (CAPA) process to capture customer complaints as well as internal failures and presented the data to management to plan for long term investments towards improvements.
Established supplier qualification process and qualified adhesive and wire supplier for marking products manufacturing process which improved overall quality of the product and reduced scrap.
Quality & Continuous Improvement Manager03/2009 to 05/2011Manner PolymersMcKinney, TX
Manner Polymers acquired PVC Compounders in 2009
Manner Polymers is a manufacturer of polymer materials for wire & cable, extrusion and injection molding applications.
Applied lean six sigma tools to improve process capability, reduce cycle time and eliminate defects throughout the company.
Reduced change over scrap in the manufacturing process by 30% while improving the change over time and establishing guidelines for production scheduling that impacted product changeovers.
Consolidated machine setting guidelines to a minimum for easy implementation and reduced machine set up time by 50%.
Managed QC and R&D lab, created SOP's and trained technicians on both QC and R&D tests, improved R&D projects turnaround time by 30% and reduced QC testing time by 20%.
Championed the transition of automotive customers from their recently acquired company (PVC Compounders Inc.) by creating new Production Part Approval Process (PPAP) and other supporting documentation.
Eliminated quality defects & scrap due to missed ingredients and reduced cost of labor by 50% by automating addition of micro ingredients in the mixing process of plastics compounding.
Automated collection of mixing batch data with PLC control and used the data to reduce defects, scrap and improved root cause analysis on external product failures.
Successfully managed the company's expansion of adding two new production lines from initiation to completion.
Improved production job packet information by simplifying layout and reduced weigh up errors in production by 50%.
Maintained ISO certification of the company by maintaining a compliant quality management system and resolving any non-conformances generated from external and internal ISO audits.
Quality Engineering Manager08/2004 to 03/2009PVC Compounders IncEl Paso, TX
PVC Compounders is a manufacturer of polymer materials for wire & cable, extrusion and injection molding applications.
Led the company's successful transition from QS 9000 to ISO 9001 in 2004 and maintained compliance thereafter.
Performed a Design of Experiments (DOE) on the critical extrusion process parameters affecting the production rate and increased the production rate by 20% while maintaining the level of product quality.
Championed successful delivery of customer product requirements through Advanced Product Quality Planning (APQP) process for all new products and improvements to existing products.
Acted as a technical field service engineer and resolved quality issues in the customer's manufacturing process of wire extrusion and injection molding.
Acted as a project manager for various engineering projects including installation of a new pelletizing system which reduced the product change over time by 50% and changeover scrap by 80%.
Managed control of non-conforming material and reduced company's rework inventory by 50% by implementing procedures for reducing internal failures and effective rework use.
Conducted management review meetings and communicated data regarding customer satisfaction, internal failures, process metrics, quality returns and supplier performance to management and presented improvement plans.
Acted as the ISO management rep for external ISO audits for the four company plants in Texas and Indiana and maintained successful compliance.
Developed training matrices and training programs to coach supervisors and operators on Lean Manufacturing Principles, Quality Management System, Compounding and Extrusion.
Managed the Quality Assurance Lab and a small group of direct reports.
MS: Industrial Engineering2004The University Of Alabama in HuntsvilleIndustrial Engineering 4.0