John Manko Email & Phone Number

Helsinki, Fi

• "Where there is no Standard there can be no Kaizen" - Taiichi Ohno, Father of TPS• Teach and develop others in TPS, LEAN Six Sigma culture, thinking and tools• Facilitate Value Stream thinking in all Product Families• Develop and deploy new grade for changing customer demands and end uses • Tune existing grades and products for optimized, cost, quality, efficiency• Ensure both internal and external customer product requirements are satisfied• Troubleshoot Quality and Production issues, develop & deploy countermeasures

Helsinki, Fi

• Troubleshot and developed Hot Band Black Strip Quality parameters• Improved Pipe Length by 1.4 to 2.8% for all Pipe & Tube Customers by adjustments to HSM Target aim• Directed Product Development of Melting and Hot Rolling Activities • Developed “Met 101” Training for all non-Mets at Calvert Campus• Trained AOD Operators and provide quality feedback for what product impacts they affected • Led A3 & DMAIC work involving surface or edge related defects related to Melt Shop or Hot Mill • Led efforts to quantify rework impact as well as rules for when or when not to rework a defect• Participated in CTC (Core Technology Competency) Group that shares technology, practices, ideas to fast-track improvements within Outokumpu Enterprise• Developed and integrated Automatic Dispositioning System (ADS) rules for AM/NS Hot Band Camber, Profile to optimize final thickness allocation and reduce processing risk• Developed rules-based logic that evaluates chemistry, hot band quality versus different Key Process Variables that defined how to optimize allocation, execute quality blocking and downgrades

Helsinki, Fi

• Taught TPS techniques, methods and pillars to Process Engineers and other OTK employees• Ingrained TPS Lean Manufacturing techniques into work environment• Developed Business Cases for new products or for new/upgraded equipment • Conducted and coordinated Product Development activities involving Melt Shop and Hot Rolling• Represented Business Demand for IT projects involving sensors, databases or analytical software• Led A3 initiatives involving surface or edge related defects related to Melt Shop or Hot Mill • Managed or assisted A3 initiatives involving yield loss in Cold Rolling Works (CRW)• Led efforts to quantify rework impact as well as rules for when or when not to rework a defect • Led CTC (Core Technology Competency) Group involving EU and Americas that benchmark technology, practices, ideas • Developed Change Management Procedures and Systems to manage process changes safely

Helsinki, Fi

• Developed Quality & Production System Troubleshooting Tools• Improved troubleshooting efficiency of Automation, Quality and Process Control Engineers• Defined and developed Key Process Variables • Reduce and control variability of Key Process Variables• Developed "Scorecards' for each coil vs. established Critical Process Variables• Worked with AM/NS Hot Strip Mill in reducing wedge, camber, edge defects and surface defects• Worked with Melt Shop Operating and Quality personnel to reduce melt defects • Worked with Melt Shop Operating and Maintenance personnel to reduce downtime/delays• Troubleshot Sendzimir Mill sheet break Root Causes related to Cold Rolling, Anneal, Hot Rolling • Investigated and pursued cost reduction efforts in all areas of Value Stream

Moscow, Moscow, Ru

• Facilitated and implemented Lean Manufacturing techniques to all areas of NLMK USA • Improved efficiency and reduced 'Muda" using 6S, Kaizen, Value Stream Mapping (VSM) techniques • Determined KPV’s that closely associate with Business Level KPI’s and developed control strategy• Installed new SPC systems / methods to reduce variation and meet KPI objectives • Trained the workers in the various workshops who will use the new NPS SPC systems • Reduced and stabilized NLMK Indiana EAF Electrical Energy by using new SPC system • Conducted gap analysis of current performance vs budgeted KPI and developed projects to meet plan• Continued to work on other Cost of Poor Quality Hot Strip Mill Projects and support Operations • Troubleshot poor quality or operating performance using various analytical tools

Moscow, Moscow, Ru

• Led several Continuous Improvement (CI) Initiatives: Yield, Surface Quality, Gauge, Profile • Modelled Finish Mill Work Roll Crowns Offline for optimized flatness and strip crown• Modelled new and existing products in offline Alstom model to assess rolling capability• Worked with OEM equipment suppliers to properly design descaling and roll cooling equipment• Provided feedback to Operations regarding the top contributors to Cost of Poor Quality (COPQ) • Determined or assisted in determining KPV product family or PRT groupings, control limits

Lugano, Canton Ticino, Ch

• Led Hot Band shape and profile improvement efforts to minimize ridging defects on cold roll products• Led cost reduction efforts for the top three defects in claim dollars: Ridging, Laminations, Roll marks • Conducted and evaluated Hot Rolling Trials on new products • Troubleshot non-conforming coils, cobbles and mill related issues with Automation and Operations• Improved Run Out Table Cooling capability by leading effort to install new laminar headers

West Chester, Oh, Us

• Led an improvement team project that increased product productivity and profitability ($4MM/Yr) improved yields (2.5%) and reduced manufacturing costs • Improved hot band physical quality / reduced cold mill strip breaks by improving speed matching between Rougher edger & work rolls and by more aggressive edging• Improved temperature homogeneity within Hot Mill Strip Furnaces• Developed downgrading parameters for re-applying non-conforming material that maximizes profitability• Evaluated and troubleshot Hot Mill defects and implemented corrective actions• Designed, conducted and analyzed plant trials to improve quality, productivity and cost• Modified Oriented and TCH furnace delay practices to optimize cost, productivity and quality

West Chester, Oh, Us

• Maximized profitability by increasing productivity, reducing costs and minimizing rework• Coordinated cross-functional teams on cost reduction, quality and productivity projects• Conducted and statistically analyzed plant experiments • Served as team leader for electrical steel improvement projects• Facilitated customer satisfaction and plant profitability by ensuring magnetic and physical quality met or exceeded all customer expectations at budgeted costs• Interfaced with both internal and external customers to resolve quality issues

Jacareí, São Paulo, Br

• Developed routings and processes for ACTCH, a Hi-B Grain Oriented Electrical Steel • Developed Hot Mill downgrade criteria for Hi-B Oriented Electrical Steels when there were Operational delays to minimize rework and yield loss impacts • Coordinated cross-functional teams on cost reduction, quality and productivity projects• Conducted and statistically analyzed plant experiments • Served as team leader for electrical steel improvement projects • Facilitated customer satisfaction and plant profitability by ensuring magnetic and physical quality met or exceeded all customer expectations at budgeted costs • Interfaced with both internal and external customers to resolve quality issues

• Process Engineer for cast tool steel backup rolls, HSLA slag pots, rolling mill housings, presses, rams, and other large castings• Engineered alloy properties for ductility, hardness, strength and fracture toughness• Improved EAF melt procedure by examining soluble O, total O, N and slag chemistries to produce a cleaner steel with a higher recovery and less refractory wear• Conducted failure investigations involving tribology, fracture & engineering mechanics• Determined composition, heat treatment needed to meet customer mechanical specifications

Washington, Dc, Us

Repaired radars, computers and associated electronic equipment for the Raytheon HAWK missile system.

Bachelor Of Science, Ceramic Science & Engineering

Certificate Of Completion, Continuous Casting Of Steel Billets, Blooms And Slabs

Certificate Of Completion, Lean Six Sigma Black Belt

Certificate Of Achievement, Total Management System (Tms) & Toyota Production System (Tps)

Advanced Problem Solving

Statistics: Strategies For Technical Problem Solving

Certificate Of Achievement, Smartview Administrator Course

Cause Mapping, Problem Solving

Safety

Statistical Process Control Training Class

Hot Rolling

How To Handle Multiple Projects And Handle Deadlines

Statistics

Metallurgical Engineering

Metallurgical Engineering

Rolling Mill Theory

Mos 5922 Improved Hawk Information Central Repairer School, Fort Bliss, Tx, Electrical And Electronics Engineering