Medical device manufacturer

Managing the growth and expansion of product lines at the Youngsville operations.

New Business Unit Start up key roll player – took the product from design concept to sellable product in 18 months. Responsible for the supplier selection and development, purchasing, quality, manufacturing engineering, scheduling, inventory management, manufacturing operations, shipping and receiving areas of the new business unit.- Managed the planning and development and operations of the Brown field facility. - Identified evaluated and selected new suppliers globally for the new product. Worked with the suppliers and the design team to design the product for manufacturability and achieved the highest quality and lowest cost. - Performed supplier quality audits, drove corrective actions and did supplier quality training on aerospace standards. - Created the inital master production schedule, production-planning system, inventory management system, and global supply chain plan for the operation.- Responsible to plan, direct, and coordinates manufacturing processes - Conceived, designed, develop and implement world class production lines to produce complex electro-mechanical devices for the airline industry.

Responsible for managing manufacturing operations, for 300+ employee, medical device manufacturer including Shipping, Production, Quality Control and Logistics. Developed strategic plans to support 30+% growth for the operational areas. Trained staff and made changes to organizational structure, operation product flow, and inventory control system to successfully support growth, while improving efficiency, quality, and customer on time delivery. Produced and shipped ~ 60,000 hand made medical devices monthly.- Developed operational efficiency tracking system - increasing efficiencies from 65% to 93%.- Implemented a transfer to production system for new products that reduced transfer time by 40%.- Trained front line supervision and managers to improve employee relations, and FDA compliance.- Used 6-Sigma and Lean Manufacturing tools to reduce manufacturing waste and enable the operations to grow 30% in 3 years with no increase in manpower, production floor space, reducing cost.- Created inventory review format that lowered backorder to customers by 40% over 10 months.- Developed inventory and distribution plan for 4 new international distribution centers.- Collaboratively started wellness program - earned AHA award for Fit Friendly Work Sites past 3 years

Recruited to improve Manufacturing Operation, Production Planning, Engineering and Maintenance areas for this 200+ person precision machining and assembly operation. Helped develop the company 6-Sigma program. Implemented systems that reduced operational spending and tracked area contribution. Developed and implemented the maintenance work order system, Production scheduling and tracking systems, engineering project tracking and performance review systems.- Championed 6 Sigma program - reduced throughput from weeks to hours - improved productivity 20%.- Implemented lean manufacturing - Improving machine uptime by 15% and reducing costs by 18%.- Developed a critical sale process for product managers to get product to customers in days not weeks- Developed international suppliers - transferred machining operations to Turkey and India.

Responsible for the Technical Team development, and managing the multi-plant transition to implement JIT and Lean Manufacturing for this manufacture of ATM’s and voting equipment.- Implemented the production quality system and operator training programs to reduce quality defects from 155 K parts per million (PPM) to 15K PPM, - Reduced the required floor space of the assembly operations by 50%.- Personally conducted team training on Lean Manufacturing, DFT, 5S, Kaizen event training, and process control. - Lead manufacturing product redesign and new product introduction effort for 5 new products in 12 months, reducing manufacturing time per unit by 45% and hardware content by 50 %.

Responsible for the Manufacturing, Maintenance, Manufacturing, Production Control, and Shipping areas. Implemented SAP ERP operations, inventory control, and Production planning modules Managed an operating Budget of 5.5 million and 120 employees. - Transitioned a 20+ year work force to understand and accept Lean Manufacturing / continuous improvement initiatives while maintaining the existing core company values and culture – reduce throughput time by 25%.- Developed customer satisfaction programs to reduce lead times from 4 weeks to 24 hours.- Reduce shipping and distribution costs over 2 years by 12%. Set up a West Coast distribution system and plant.- Reorganized the material control department to reduce slow moving and dead inventory by 5 million dollars