QUALIFICATIONS
• Operations Management – Hands-on leadership, team building and supervision; budget development and management; P&L responsibility; operation start-ups; data driven decision making; environmental, safety and health management; capital investment and installation; solution driven improvement leader; production scheduling and maintenance; supply chain development & management; accounting, IT, purchasing
• Six Sigma Champion – Six Sigma Black Belt, customer-focused project identification, direction and management; mentor; DMAIC, statistical data analysis, DOE, continuous and sustained improvement.
• Lean Manufacturing – Implementation and management; 5S, value stream mapping, visual work instructions, visual workplace, total productive maintenance, metrics development and management, Kanban systems.
OPERATIONAL MANAGEMENT EXPERIENCE
HydroGen LLC (Phosphoric Acid Fuel Cell Power Systems), Versailles, PA 2/2006 - 10/2008
Senior Manufacturing Manager
• Leadership of phosphoric acid fuel cell components manufacturing & assembly; 50 manufacturing personnel, $20MM budget
• Built highly motivated, talented manufacturing team, installed manufacturing equipment and resurrected original manufacturing operations
• Delivered complete 400KW fuel cell demonstration module in two years.
• Established plans for doubling output including quality system development and implementation of Lean Manufacturing principles.
Johnson Lean Consultancy (Lean Manufacturing Implementation) 6/2004 – 11/2005
Independent Consultant
• Six Sigma project leadership and facilitation of Lean Manufacturing training in client facilities
• Led a Six Sigma rework reduction project resulting in 50% reduction in rework
• Facilitated training and implementation of Lean Manufacturing; 5S, Visual Work Instructions, Value Stream Mapping, Total Productive Maintenance, shop-floor metrics and Kanban development
American Video Glass Company (Television Glass), Mt. Pleasant, PA 1/1997 – 5/2003
Operations Manager
• Provide leadership to a 60-member production line for manufacturing panel glass for 32” flat screen tubes for Sony televisions
• Responsible for supporting $40MM in sales and managing $8.5MM operating budget
• Improved quality by 25% and productivity by 48% over previous year’s performance
• Coordinated the plant-wide “Sony Six Sigma” training and implementation program providing technical guidance to project leaders in the selection of projects and use of Six Sigma tools and represented business unit on site Six Sigma Steering Team
• Received 2002 President’s Award for Productivity Improvements
Customer Quality Engineer (@Sony Electronics, Rancho Bernardo, CA)
• Coordinated performance quality improvement activities at customer’s facility
• Identified major quality issues regarding glass breakage in CRT manufacturing resulting in 50% reduction in defects among four production lines
• Worked with customer management, production, engineering and quality personnel to improve coordination of all activities related to the consumption of CRT glass
• Received 2001 President’s Award for Customer Service
Technical Team Leader
• Provided technical team leadership for the receipt, installation and start-up of hot forming equipment for CRT panel glass in a new facility
• Trained personnel, developed procedures and process specifications. Incorporated process improvements.
• Developed tooling, equipment and process parameters for four new products
• Implemented comprehensive statistical quality control system for panel forming operations
Aliah, Inc., (Facilitated Decision Making Software, Analytic Hierarchy Process), Pittsburgh, PA 1/1993 – 1/1997
Vice President - Operations
• Led team of software engineers, production, quality assurance and delivery personnel for software products
• Adapted AHP to practical applications of root cause analysis, quality function deployment and failure mode and effects analysis
• Managed projects for developing software application packages, establishing quality assurance procedures and testing
• Provided round-the-clock Help Desk support for customers worldwide.
ABC Rail Corporation (Gray Iron Foundry, railroad car and engine brake shoes) 7/1989 – 1/1993
Process Control Manager
• Designed and implemented comprehensive Quality Assurance system in conformance with Association of American Railroads requirements
• Provided technical and team leadership of equipment and process improvements resulting in 45% improvement in productivity, 60% i...
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