Stephen Jones Email and Phone Number

New equipment, product and process improvement, quality systems, lean six sigma, problem solving.

Business process improvement, lean six sigma program, medical quality assurance, quality engineering, fulfillment center quality plan, strategic planning.

Project management for telematics implementation across 6000 vehicle service fleet. Implemented customer satisfaction and CI program across all branches in the West Region that improved NPS (Net Promoter Score) from 38% to 71% across the West Region in seven months. Responsible for regional BBP improvement plan and results across ten key business metrics. Extensive benchmarking, problem solving, value stream mapping and best practice sharing sessions.

Responsible for Lean, Six Sigma and continuous improvement project execution across four metal-forming, one seat track assembly, and five foam processing plants in North America ($30M+ savings each of the last six years), process capability improvement, training and mentoring of CI personnel.● Project manager for $30M+ annual savings in conversion costs.● Trained, mentored and certified 60+ Black Belts, 100+ Green Belts, 100+ Lean Implementers● Improved process capability to 1.67+ across 54 key dimensions for 08 Honda Accord track launch● Introduced non-destruct testing for arc welding, reducing scrap by 90% in 3 months.● Resolved over 30 potential serious welding safety concerns at San Antonio, TX plant in 2 months● Implemented accelerometer based testing of seat tracks, eliminating 900k+ direct labor.● Reduced helium usage on laser welding through Taguchi DOE by 50%, saving $1M+● Reduced destruct testing by 75% on laser welding through DOEs, saving $500k+● Reduced continuous conformance testing by 40% on seat tracks, saving $800k+● Increased machine utilization on roll forming of seat tracks through lean/DOE by 14%● Removed postcure oven for foam pads via chemistry DOE in two foam plants, saving $600k+● Created line balancing tool for foam lines, improving utilization by 6%.

Charged with “re-energizing” Lean at Johnson Controls in North America and Asia/Pacific. Development and delivery of lean training and certification in person, via the Internet and training books, posters and videos. ● Created JCMS self-assessment (quarterly audit and improvement process)● Created “Lean Thinking in Process Mapping” for improving transactional processes● Trained & certified 100+ Lean implementers● Led 100+ 5S, Kaizen, Errorproofing, Quick Changeover sessions in 50+ plants…o Increased waterjet cutting capacity 60% in Australian interiors planto Reduced changeover time by 40% in Canadian foam planto Reduced utility costs in Tennessee foam plant by 50%o Reduced WIP inventory by 40% in Michigan plastics planto Led a four month “Train the Trainer” for Australia, Thailand, India, Singapore & China.

Internal consultant responsible for lean training, “lean model line” installation across facilities in North America and Europe.● Installed “heijunka” level production system at MA plastics plant to increase utilization by 26%● Implemented TPM at a relay mfg plant in Italy, reducing machine-related downtime by 85%● Implemented kanban system for AZ airbag plant to reduce inventories by 25%● Used Taguchi DOE to optimize “pour-in-place” gasket cell productivity by 30%

Manager, Manufacturing Engineering, (1995-1996)Responsible for new product launch and manufacturing equipment installation to Reynosa MX switch mfg. Led a staff of 15 (engineers, technicians, metrologist, machinist) in the Center of Excellence. P&L responsibility switch product lines. ● Implemented internal rapid prototyping (FDM), reducing assembly equipment lead time by 15%.● Introduced rapid tooling, reducing assembly equipment signoff time by 10%● Introduced disciplined Manufacturing Readiness Review process, improving launch quality● Developed 5 Year Mfg plan to tie equipment spending to sales plan● Plant “Champion” for Canadian electronics plant

Studied Japanese language and culture at Vanderbilt University in TN for 3 months and in Yokohama, Japan for 1 month. Moved to Toyota City, Japan to begin Fellowship at Takaoka Plant (mfg Corolla and Tercel). Trained in all aspects of Toyota Production System, new product launch, quality circles, kaizen, etc. All training was "OJT" or on-job-training along with Toyota workforce and new hires on plant floor.