John Vaughn Email & Phone Number

Santa Fe Springs, CA, US

Seasoned Operations executive eager to assist client businesses to systematically minimize waste and reduce variation in order to provide higher quality, improved delivery times and better value to customers. My proven methods focus on employee education, engagement, and retention to ensure sustainable improvements that are designed with pride by incumbents.

Grand Rapids, Michigan, US

Ubajara, Ceará, BR

Dallas, TX, US

• Aligned 56 engineering resources at six sites, including USA, Mexico and Tunisia; influenced and mentored site leaders to define clear objectives (Hoshin) and visually track KPI's using a standardized "9-Box" format
• Performed intensive on-site assessments and developed first-year Lean Roadmaps for newly acquired and partnered businesses (ETI, Exos, Bell Horn) along with Blackstone Partner, COO and SVP of Lean and Enterprise.
• Deployed and fostered our Shingo Prize-winning continuous improvement culture across Operations, Sales, Finance, Accounting, and with Suppliers, by facilitating strategic kaizen blitzes and mentoring in lean.
• Inspired SVP, VP and Director-level budget owners to successfully accomplish our 2011 corporate capital budget objectives of $38million within 5% favorable variance of plan
• Gained executive leadership team buy-in to fund and implement a corporate-wide Enterprise Asset Management system to standardize equipment maintenance procedures and improve fixed asset financial traceability
• Volunteer with the Association of Manufacturing Excellence (AME) as a Manufacturing Excellence Award site assessor

Carlsbad, California, US

• Provided leadership and training to an operations staff of 350 to adopt Lean Manufacturing (5S, PDCA, VSM, Visual Systems, Standard Work, SMED, Poka-Yoke and Kanban), which resulted in a 20% efficiency improvement.
• Empowered and nurtured production team members, leads and supervisors to be front-line contributing thinkers that ultimately accelerated and drove our Lean pursuits
• Implemented Six Sigma tools (Global 8-D, MSA, Capability Analysis, DOE, Capacity Analysis, SPC, Discrete Event Simulation and DMAIC) to achieve 80% improvement in 2009 year-to-date Average Outgoing Quality
• Implemented Theory-of-Constraints line management practices in the Fusion driver head production area to achieve throughput and efficiency improvements of 114% and 150%, respectively
• Managed a direct staff of nine; qualified 15 new product families and several semi and fully-automated assembly systems into production each year
• Concurrently directed the 19 personnel of our China-based FICE office to ensure that supplier quality issues were either avoided or effectively resolved

Chicago, Illinois, US

• Assembled and led two international teams of 4 - 6 engineers on the NPI Quality DMAIC Projects, which achieved the target $1.32M warranty returns cost-savings for the CDMA business
• Mentored Black and Green Belt candidates to complete their DMAIC projects, which returned $1.1M in cost savings; the candidates earned their official certifications as a result
• Increased CAR process efficiency by 117% by implementing IBM Rational ClearQuest software; achieved annual engineering cost avoidance of $791K

Chicago, Illinois, US

• Managed an international team of 9 Electrical Engineers to address the CompactPCI Product Operation’s average of 12 product re-spin projects per year and all Customer Problem Reports as they arose
• Generated and revised procedures, interviewed with auditors and successfully renewed our ISO9001 Certification
• Led a series of engineering "Tiger Teams" to successfully transition and re-qualify equipment and processes to a brand new manufacturing site in Nogales, Mexico

• Successfully designed and implemented Baan ERP multi-site software to improve clients’ billing efficiency
• Developed value propositions that summarized technical, functional and cost scope; won two additional contracts

Tempe, Arizona, US

• Formed and championed a cross-functional outsourcing team that successfully developed and deployed a corporate-wide make/buy cost model to enable effective outsourcing decisions
• Created purchasing contracts and JIT stocking agreements to improve efficiency of U.S and Taiwan-based suppliers

Tempe, Arizona, US

• Successfully designed and launched 9 StarMax Macintosh-compatible computer systems into high volume production
• Managed domestic, Taiwan and Korea-based suppliers of sheet metal, plastics, industrial design, safety and regulatories

Chicago, Illinois, US

• Supervised a team of 10 engineering resources through design, test, and production launch phases; won the Ford Motor Company sole-supplier contract for Differential Pressure Exhaust Recirculation Sensors
• Engineered and launched the Ford EVAP Differential Pressure Sensor to increase sales by $40 million, annually
• Authored U.S. Patent 5,741,975, Media Isolated Differential Pressure Sensor Design and Fluid Injection Method

Mba, Business Administration

Bs, Mechanical Engineering

Lean Enterprise Certification

Six Sigma Black Belt Certification

Six Sigma Green Belt Certification

Education record