Experience

8/2011-Present Lowell Consulting, SME/Consultant/Analyst: Specialization in BPR, Lean/TPS, ISO, Quality Systems, EHS Processes, Process/Performance Improvement & Excellence, and Operations/Control Analysis

Contractual improvements for improved safety, quality, customer relations, CIP, cost, control, processes, and cycle time utilizing Six Sigma, Lean, root cause analysis, business & operations analysis, gap/risk analysis, process mapping, BPR, BPE, and related continuous improvement methodologies and tools. Project leadership with staff, management, suppliers, customers, and external groups to identify potential process improvements, productivity increase opportunities workflow enhancements, problem definition, issue identification and process development using problem solving principles and past experience. Responsibility for developing, enhancing and maintaining process incl. operational information, metrics, and models.

Summary of recent engagements: Initiated and managed new Lean/Six Sigma projects for both front-end and back end processes. Aligned improvement, control procedures, change and validation efforts to balanced scorecard goals, business/quality control, & performance servicing. Increased use of lean /TPs methodology across the business infrastructure and internal processes including FMEA, RCA, CTQ, SDLC, CMC, Value Stream, performance improvement, MES integration, workforce analysis, responsibility management, SIPOC, etc. Increase value of IT system by aligning data and methods to drive key metrics in production, distribution, purchasing, and supply-chain. Pre-ISO 9001 certification evaluation & audit.

Sample results: Reduced operational costs by 10-18%
Credit approval down from 93 to 11 days
Transaction settlement time down from 700 to 60 minutes and first time correct up from 97% to 99.6%
Expanded use of bar-coding to reduce operations time by 50%

5/2006-7/2011 Quality/EHS Director, Circuitronics/Q-Fab/Network Circuitry LP, Irving, TX
1/2011-7/2011 ISO Management Representative/EHS Manager, W-Tek, Irving, TX

Responsible for Quality Management System, EHS, QC, lean initiatives and all Improvement programs
Site management for ISO 9001 quality management system for multiple electronics manufacturing firms including all process management, quality & operations control, continuous improvement, green SCM, lean-six sigma programs, ISO qualification (9001, 13485, 14001), training programs, production/document control, inspection/supplier quality, EHS, SCM, and process definition/improvement. Brought two companies to ISO certification from nothing within eight months. Scope of technical responsibility includes: process analysis and performance improvement, lean systems analysis and continuous improvement, improvement of reliability-centered maintenance programs, logistics, and management of business analysis/IT projects. Started and continue classes in SPC, ESD, Toyota Production System concepts, IPC-approved electronics manufacturing, root cause analysis & statistics. Implemented P2-A5-Lean-EHS integration and Lean Six Sigma safety improvement.. Direct efforts to improve operational service delivery, and manufacturing & MES methods/processes for production. Provide site improvement to ensure compliance with quality, lean, operations, & environmental, health, and safety (OSHA, EPA) regulations & training.

Sample results: Reduced operational costs by 12%
Reduced average assembly time by 10%
Increased inventory cycles by 200%
Took 2 companies to ISO certification in 6 months
Improved 1st pass quality by 15%

2002-5/2006 Confidential, Owner & Principal Consultant, Dallas, TX

Specializing in BPR, CIP, operations, quality, improvement & manufacturing/product management consulting: 
Technical consultant or Engagement Manager for OEM companies for product/production engineering, general manufacturing, electronics production, MES/ERP/SCM/IT operations/process improvement, lean-six sigma-AGILE programs, quality improvement, factory automation, infrastructure/CTQ revisions, business analysis, service, procurement, process reengineering, performance improvement, change management processes, safety/EHS management, ITIL, & lean/agile manufacturing. Barcode/RFID metrics tracking and analysis for inventory/E-business between international suppliers & clients, integration of facilities, equipment, distribution, materials, systems and personnel with recommended process improvements, application of mathematical, process, or simulation models for optimizing floor space, minimizing material handling, MES, and detailed flow analysis. Verticals served: Automotive, High-Tech, Electronics, Chemical, Finance, IT, General Manufacturing, Plastics, Consumer Goods, & Healthcare, Insurance, Aviation, Technology, and Consulting

Sample engagements:

• Design of BPI projects to improve supply chain management, manufacturing and services. Contractual improvement applying lean strategy across the client enterprise. Review of client key performance metrics, benchmarking “Best Practice” companies and training workforce in lean methods. Specific lean expertise includes Value Stream Mapping, 5S, RSIC, DOE, TQM, lean accounting, TPM, Kanban, Visual management and poka-yoke/root cause analysis. Analysis of cost effectiveness and efficiency of compliance & metrics incl. balanced scorecard introduction, IT/operations analysis, inventory control, MES/MRP, quality process analysis, work flow systems, and compliance monitoring by automation. Eliminate the waste of manual/paper processes by leveraging the use of technology through electronic forms, data automation and Portable Electronic Devices or PEDs.

Develop current processes models, conduct assessments, document findings, identify gaps, analyze, measure maturity, and develop recommendations for implementation and improvement in business, operations, service, distribution, SCM, SDLC, CMMI, and production management processes based on best practices. Lead capacity planning analysis, MES quality systems, process bottleneck, agile/lean initiatives and cost benefit analysis. ISO 9000/9001 preparation/audits and QMA planning. Also, develop, implement and direct the quality control and formal continuous improvement process. Lead auditor for ISO 9000:2001 quality audits or pre-audits. Analyze front office processes incl. Order-to-Cash, Purchase-to-Pay, & Record-to-Report

• Sample list of clients: SoftBrands, Assembly Solutions Inc., Oasis Semiconductor, MC Assembly, Abbott Labs, McDonald Technologies, Honeywell, Lawrence Manufacturing, Celion Technologies, Turck, TI, Photodigm, ST Microelectronics, Washington Mutual, Megladon Manufacturing Group, Celestica, Sanmina, Tetra Pak, Efore, Elcoteq Network, PSSI, Pepsi, Cumberland Bank, Genesis, Thermon, Medtronic, Stryker, Tenet, Braun Medical, American Vault, Solectron, Micro Power, Baldwin Americas, Potter Electric Signal, Silent Knight, Teco Switch, Sovereign Circuits, Littlefuse, MC Assembly

Sample results: Reduced operational costs by 10-18%
Reduced cost of manufacture 8-14%
Reduced purchasing time by 20%
Lead four firms to ISO certification
Cut takt time by 15%
Cut transaction cycle time by 50%
Increased profitability 200% in 14 month

2000-2002 Confidential, Account/Engagement Manager, Richardson, TX

Managed consulting in Europe & the US with electronics manufacturers to increase yield, reduce materials defects, qualify processes/control and improve manufacturing performance with the target goal of reducing time-to-volume, time-to-market, process & lean efficiency, and improving profitability with integrated materials management, capacity, supply-chain, software, and inventory control. Process & performance improvement and client business analysis strategy integrating web-based, real-time AGILE based-factory-customer interaction. Responsibilities include managing consulting team, “hands on” process development & control, APC, SDL, MRP/MES integration, SCM, PLM, process analysis, process safety management, materials management and active client interactions throughout the executive and engineering levels. Real-time, international inventory management, logistics, RFID and order fulfillment.

• Responsible for Business Development & Sales, incl. revenue and margin, & management of teams, within each account. Establish Pricing Model for client business and lead contract negotiations with clients & partners. Formulate and manage bookings, PR, & marcomm. Ensure all actions taken to achieve quarterly / yearly targets. Ensure Quarterly Reviews with each strategic account to maintain account relationships and define short and long-term goals. Train clients on product. P&L responsibility for accounts.

Sample results: Responsible for $12M in sales
Improved customer quality and efficiency by 18%
Increased inventory turns by 25%
On time delivery improved by 23%
Engineering productivity improved by 25%
Equipment uptime increased by 45%

1996-2000 Confidential, Principal Consultant & Owner, Austin & Dallas, TX

Built firm for sales, & management consulting: Acted as technical sales representative or business analyst for a variety of companies selling OEM software, hardware, electronic components, materials/supplier analysis, business/data analysis, lean/AGILE conversion, quality, & process/profitability improvement. Technical sales support for e-business (SCM, B2B, CRM, MRP, EAI, DP,MES) introduction to high-tech, manufacturing & telecom verticals. Also contracted for ISO 9000/9001 QMS development, process control, RFID, quality system audits, & integration of balanced scorecard. Lean Six Sigma safety improvement, supplier analysis, proposal development, control, audits, & presentations (customers, trade shows), manufacturing, inventory/warehousing, MHE, distribution, and logistics consulting. P&L responsibility for company. Account management and international manufacturing coordination. Verticals served: Automotive, High-Tech, Electronics, Chemical, Finance, IT, General Manufacturing, & Healthcare

• Client engagements included analysis ofcapacity/constraints, capacity-cycle time trade-off,

Quality, SPC & lean methods, and cost analysis of maintenance, production control, and other operations. Specialized consulting on process flow analysis, materials cost analysis and cost reduction, lean manufacturingapplications, and education & training of cross-functional teams in charge ofproductivity, DFSS, DMAIC, throughput and cycle time improvements in a production environments. Develop quality/improvement systems and training programs.

Sample list of clients: Samsung, Chartered Semiconductor, Oracle, TI, Flextronics, Applied Materials, 
Philips, Southwestern Bell, VLSI Technology, Systems Research, Corpus Inc., Dell, Abbott Labs,
Tech Venture Partners, Perdanales Electric Co-op, Honeywell, Turck, Solectron, and Westinghouse

Sample results: Reduced inventory by 25%
Reduced fulfillment CT by 40%
Increased gross profit margin by 7%
Streamlined operations by converting to pull production from push
process

1990-1996 Member (\'89-\'90), Senior Member (\'90-96), Technical Staff, Fab 25 & 
Director (\'91-\'96), Production Support/MIS Lab (Austin), and Systems Integration Manager (\'89-\'90) (San Antonio), Advanced Micro Devices

• Responsible for IT management and implementing integration, testing and quality standards throughout MRP/IS/IT/ERP organization over four manufacturing operations included were installing and supporting automation systems for fabrication equipment; infrastructure reform and improvement; organizing, tracking and driving projects for relational database access, Internet/Web WIP configuration, and general/end user support. Created, maintained and managed capacity and resource planning methodologies for all internal and outsourced manufacturing facilities. Management skills included IT architecture assessment, IT operations analysis & strategy, operations management, internal BPR consulting, & IT risk management. Evaluated and managed in-house developed and commercially implemented test, data retrieval, DP, SCM (i2), materials management & MES tools. Led initial efforts in site introduction of UNIX, workstations, supply-chain management, LAN, WAN, and the internet. Accountable for establishing and implementing SPC, Six Sigma, DMAIC, DFSS, JIT, and lean standards. Also responsible for creating and introducing lean/AGILE & TPS methodology, ITIL, and change management enhancements, for hiring, setting expectations and for mentoring, evaluating, training, and coordinating within department(s) of responsibility.
• Responsible for developing and maintaining business, materials, and factory systems/process models, and ISO qualification; Managed program management group, coordinating procurement, production and delivery of all material. Responsible for $50+M in IT capital. Application of sophisticated industrial engineering/operations research techniques to support manufacturing processes.
• Responsible for developing and maintaining business and factory systems/process models, standards for ISO qualification including internal and supplier quality audits, quality documentation & handbooks, and maintaining quality standards. Completed first ISO 9000 qualification for site. Responsible for implementing QFD quality practice in manufacturing (SPC, DFT, JIT, Kaizen, Lean mfg.). Design Engineering; CAD/CAE/CAM, Software Engineering; Field Engineering, Installation, and Maintenance; Contract Compliance; EHS; and HR. Managed multiple 100+man days projects with varying levels of complexity to successful completion. Directed global development and implementation of the computer integrated manufacturing systems including equipment connections, WIP tracking, equipment maintenance systems, quality management systems, and plant scheduling

1985-1990 Production/Program Director,Confidential, Wilmington, DE (& Ipswich, UK)

• Managed and personally developed fab production of InGaAlAs lasers using MOVCD, manufacturing infrastructure and all silicon and GaAs TX/RX IC\'s, WDM, Optical Amplifiers, Optical Waveguides for FDDI, SONET; Later also managed design, CAD & marketing for telecom/datacom fiber optic products
• Responsible for product & PCB (SMT, TH) production and operations budget & personnel
• Development of component & SPICE-level models for customer applications Electrical and optical design/models of modules for telecom and datacom products incorporating hybrid MCM technology & 1300nm optical devices; Full product test responsibility.
• Part of a two-person management team responsible for building and operating a 75000 sq. ft. manufacturing facility from scratch.
• Managed all external (outsourced) manufacturing for mechanical & electrical components
• Responsible for safety, quality/SPC, productivity, warehouse, inventory, CNC machining, distribution & costs.
• Implemented corporate quality/inspection system for manufacturing, ISO9000 and customer reports

1982-1985 PIPE Product Line Manager (VHSIC), Confidential, Dallas

• Test chip definition and layout for VHSIC CMOS modules and layout
• Participated in gate formation, isolation, & MLM modules for 0.7-0.5 micron CMOS.
• Product line P&L responsibility
• Responsible for design, testing and manufacturability of Pipelined Image Processor Element (PIPE) chip for IR-FIR acquisition/sensor systems, CCD-FPA, and DSP applications for image processing.
• Managed sensor module design through production, and qualification

Related Job/Computer Skills 
Technical Skills: 
Capacity and inventory analysis, bottleneck management, and theory of constraints; Time and motion studies and market analysis tools, e.g. MOST Cost analysis, economic engineering; Facility and equipment layout methods; High volume manufacturing with extremely tight quality, reliability and cost requirements; Econometrics, Operations research, SPC, Six-Sigma, DMAIC, CFM, DOE, FMEA, QFD, CFD, PERT,CPM, Taguchi Methods, TRIZ, Statistical sampling and analysis; DFT, CMMI, GMP; Industrial Codes: UBC,UFC,NFPA,OSHA,SEMI; NPI, DFR, capability studies, first article/first piece layouts, 8-D problem solving, FA, calibration “uncertainty” (A/B data), RSIC, risk analysis for ISO, Weibull Analyses.

Lean TPS principles, incl. waste elimination, pull systems, Kanban, Kaizen, visual workspace, one piece flow, flow manufacturing, set-up reduction, standardized work, variation reduction, error proofing, total productive maintenance, design for manufacturing, ergonomics, lean replenishment systems and level loading, Crow/Duane Growth Models, Time Based Tools: Cycle time, Product Life Cycle Management, Concurrent Engineering, Pareto techniques, Ishakawa diagrams, Payntor charts, COT. Lean Practice: Value Streams, TOC, TPM, TQM, TRIZ, 5-S, 8-D, Gage R & R, Heijunka, KTA & Root Cause Analysis.

Languages: French, German, Spanish with some Japanese, Italian & Chinese (Mandarin)

Computer Skills: Visual C++, C , VB 5.0, SAS 8.2 (Macros, SAS/SQL,SAS-Graph, SAS-Stat, Warehouse Admin, ACESS, S-Plus),RS/Series,PL/SQL, SAP ABAP/4., IEEE 488/GPIB, & GUI, MS Windows, Windows 95/98/00, Win NT,HP-UX , DEC, VMS and X-Windows/UNIX.; MS(Office, Project, Access, Visio, Solutions, SQL); Prism, ETI, Cognos, LabVIEW, Informix, GEM/SECS. UNIX, OODB: QI, Minitab, ControlLogix, ControlNet, DeviceNet, AutoCAD, Stat Graphics. MES technology: Honeywell, Aspentech, & PSI Data systems

Quality Processes (ISO 9000/9001:2008, TS 16949, AS9100, Six Sigma (Green Belt certified, 1991, last renewed: 7/2011), SPC, JEDEC, AEC-Q100/Q101VR, CMMI, Kaizen, TQM, TQC, QFD, COO, COT). MRP/MES systems, Promis, WorkStream;Consilium,FasTrack,LIMS;JDE OneWorld (supply chain); Oracle(v10.7/11i/11.5.7, INV BOM, Discoverer, Darwin, WIP, ENG, MRP, CAP, CRM, PIM, AIM, SCM, OSFM), DB 8i/9, E-Business Ste. Manugistics, OPM, Manufacturing Scheduling, Warehouse Management, Inventory Management, Mobil Supply Chain, Adv Supply Chain Planning, Business Objects 5.1, ACT, Goldmine, Demand Stream, Fourth Shift, i2(FP,DP,RHYTHM), MES (Honeywell, Aspentech, PSI); SAP(MM,FI/CO,PP,WF,QM,PM,PS),PeopleSoft V7.5(SA,PM,PP,ENG, Red Pepper); IBM MQSeries, MQ Workflow; WinSPC, RosettaNet Standard; Win Runner, Matrix One. Project methodologies: SDLC, Agile, ITIL, PMP, PMBOK, Clarity, Waterfall, SIPOC analysis, process maps, and RACI

Education

M.B.A. (1997) Confidential, Austin, TX.
Ph.D. (1982) Applied Physics Confidential, Chelsea College 
M.S. (1974) Applied Physics, Confidential 
B.S. (1972) Mathematics/Physics, Confidential