Faisal Abdullah Email & Phone Number

Conducted business analysis and played a major role in establishing plans to free-up capacity by more than 30% in the Rim Manufacturing and Wheel Assembly Operations.Developed KPI dashboards throughout the entire organization which helped our Managing for Daily Improvement (MDI) program. These KPIs played a major role in developing improvement opportunities on a quarterly basis and resulted in the execution of several Six Sigma based projects and Kaizen events. Substantial improvement in first pass yield, productivity, manufacturing lead-time, and past dues in less than 12 months. Led efforts to relocate all distribution activities to a new location. Coordinated all inbound and outbound activities and completed the relocation on time and within budget.Led several quality improvement projects which helped reduce PPM levels by more 50% and Cost of Quality (COQ) by more than 25%. Worked with our steel, chrome plating, and powder coating suppliers and jointly developed plans to improve the quality of finished Chromed and Painted wheels.

Corporate

Corporate level responsibility for 14 manufacturing and internal supply locations across the United States and 2500 employees. Responsibilities include the development of the overall operational excellence strategy and assisting the locations in establishing the tactical plans in support of the corporate philosophy.Led the development and implementation of a highly specialized lean training program. More than 50 certified Lean Specialists on staff executing Kaizen Events on regular bases. As a result, we completed more than 350 Kaizen events, implemented more than 15 Poka Yoke projects, addressed more than 1,200 safety items and resolved more than 500 quality issues in two years. Developed operating methodology for the Model Line Kaizen (MLK). The objective of the MLK is to improve key business processes across multiple business units/locations utilizing cross-functional teams. Solid results achieved in Service, Distribution, Productivity, Quality, Order Entry and Total Productive Maintenance (TPM).

Ontario, California

Led the effort to transition the quality system to the TS-16949 in less than six monthsActive role in relocating product lines to China. Championed activities among all functions between the receiving and the passing teams. Established a comprehensive qualification plans and coordinated all PPAP activities internally and externally. Improved the Plate Fin product line productivity from 83% to 104% in less than 5 months and reduced scrap by more than 50% over the same period.

Corporate

Corporate level responsibility for 12 worldwide media (CD/DVD) manufacturing sites and more than 1500 employees serving Dell, HP, Microsoft, Apple, Gateway, Oracle, Logitech and many other high tech leaders.Led the effort to obtain ISO 9001:2000 transition & certification in four different locations in the US, Canada and Ireland.Developed MPQ (Manufacturing Process Qualification) to standardize Zomax product release and production system. This involved driving culture change in multiple facilities that were from acquired businesses with different cultures. Developed a highly customized web-based project management program that won Oracle’s Innovation Award in 2004. This program used extensively to track key development projects with Microsoft, Dell, Oracle, Apple, Logitech and many other High-Tech Customers

Corporate

Corporate level responsibility for 11 worldwide Marketing, Design and manufacturing locations and more than 3000 employees serving General Motors, Ford, Chrysler, Walbro, Siemens, Cisco and many others. My responsibilities extend to providing leadership in the areas of Quality Systems, Supply Chain Management, International Standards Certification, Six Sigma, Continuous Improvement, Problem Solving, Elimination of Waste, and the Development of Reliability Goals & Measurement Techniques. Led the efforts to obtain customers’ acknowledgement of relocating the $30 million Thick Film Operation from Ontario, CA to Huntington, IN. Relocation was completed on- time, within budget and with zero interruption of shipment to customersLed efforts to obtain Ford Q1, QS-9000 & ISO 9000 certifications in four different locations in the US, Mexico and the UK. Ford used our above and beyond Q1 achievements as a model for other supplier to follow.Coordinated all APQP, PPAP, FMEA and new product qualification activities across the organization.