Experience
2/2012-Present Lowell Consulting, Dallas, TX Owner/Analyst/SME; Specialization in Lean/SS/TPS, ISO, Quality Systems, EHS, Process Improvement and Operations Excellence/Analysis
Provide expertise and solutions for global quality, improvement, engineering/maintenance standards and processes; implement innovative improvements for operations KPIs for high tech, discrete, and general manufacturing, and EHS, including: Training, audits, diagnostics, metrics, & ISO standard procedures. Contract Supplier QA; Contract ISO/EHS pre-audits & Internal Audits; Process development or improvement for client focus areas (e.g., Engineering, Supply Chain, Front-End, Back-end, Production and Maintenance), customer satisfaction, EHS, CIP, safety processes, and FO/BO infrastructure.
Sample of recent engagement:
Acting Corporate Quality/EHS Manager (Contract), $20M Multi-site electronics company
Responsible for Quality Management System, EHS, QC, lean initiatives and all Improvement programs across multiple sites (TX, NJ, PA, & PRC). Corporate management for initial implementation of ISO 9001:2008 quality management system for multiple manufacturing sites including all process management, quality control, continuous improvement, lean-six sigma-SPC programs, IPC 610/J-STD training programs, production/document control, ESD control, inspection/supplier quality, EHS, and process definition/improvement. Scope of technical responsibility includes: overall management of all QC personnel, composition of ISO system documents/manual/procedures, startup of lean-six sigma analysis, RCA, service, and continuous improvement, alignment programs for management goal realization, and management of improvement projects. Started six sigma monitors on all production equipment. Direct efforts to improve site EHS, ISO 14001 compliance and policies, and manufacturing methods/processes for production. Revised inspection procedures to comply with AS9100 (for clients Bombardier, Raytheon, etc.) and IPC 610 standards. Provide site management to ensure compliance with environmental, health, and safety (OSHA, EPA) regulations & training.
Sample results: Reduced operational costs by 15%
Updated ISO system to 2008 standard
Implemented ISO 14001-based EHS Improvement system
Automated tracking for REACH data from suppliers
Implemented ISO 13485 system for Safety Process Management
5/2006-7/2011 Quality/EHS Director, Circuitronics/Q-Fab/Network Circuitry LP, Irving, TX
and ISO Management Representative/EHS Manager, W-Tek, Irving, TX
Responsible for Quality Management System, EHS, QC, LSS, TPS and all Improvement programs:
Site management for ISO 9001 quality management system for multiple electronics manufacturing firms including all process management, quality control, continuous improvement, green SCM, lean-six sigma programs, ISO qualification (9001), or compliance (13485, 14001, AS9100, CMDR, 21 CFR), training programs, production/document control, inspection/supplier quality, EHS (OSHA, EPA, HAZMAT, wastewater), SCM, ESD control, and process definition/improvement. Brought two companies to ISO certification from nothing within eight months. Scope of technical responsibility includes: process capability analysis, safety processes, and defect elimination, lean implementation, customer satisfaction, and continuous improvement, improvement of reliability-centered maintenance programs, and management of business analysis/IT projects. Started and continue classes in SPC, ESD, Toyota Production System concepts, IPC-approved electronics manufacturing, root cause analysis & statistics. Implemented P2-A5-Lean-EHS integration, and Lean Six Sigma-based safety improvement. Directed efforts to improve site EHS, disaster & business recovery management, and manufacturing methods/processes for production. Provide site management to ensure compliance with environmental, health, and safety (OSHA, EPA) regulations & training.
Sample results: Reduced operational costs by 12%
Reduced average assembly time by 10%
Decreased on site accidents by 50%
Increased inventory cycles by 200%
Took 2 companies to ISO certification in 6 months
Improved 1st pass quality by 25%
Installed safety process management/ISO 14001
2002-(5)2006 Lowell Consulting, Owner & Principal Consultant, Dallas, TX
Specializing in BPR & manufacturing/quality/EHS process management consulting:
Technical consultant or Engagement Manager for OEM companies for product/production/engineering (discrete, electronics, high-tech) , MES/ERP/SCM/IT operations/process improvement, lean-six sigma-AGILE programs, ITIL, quality improvement, customer service improvement, factory automation, business analysis and process reengineering, production/APC/LSS control, CIP, process safety management, & lean/agile manufacturing. Barcode/RFID metrics tracking and analysis for inventory/E-business, plant & operations management, integration of facilities, equipment, materials, systems and personnel with recommended process improvements, application of mathematical, process, or simulation models for optimizing floor space, minimizing material handling, and detailed flow analysis.
Contract quality audits (internal audit, safety, supplier quality, pre-ISO qualifying, production efficiency). Verticals served: Automotive, High-Tech, Medical manufacturing, Electronics, Chemical, Finance, IT, General Manufacturing, & Healthcare
Sample engagements:
• Design, BPM, APC, supply chain management, international manufacturing and after-sales services Contractual continuous improvement applying lean strategy across the client enterprise. Review of client key performance metrics, benchmarking “Best Practice” companies and training workforce in lean methods. Specific lean expertise includes Value Stream Mapping, 5S, DOE, TQM, lean accounting, TPM, Kanban, Visual management, management of Change, CIP, and poka-yoke/root cause analysis. Analysis of cost effectiveness and efficiency of compliance & metrics incl. balanced scorecard introduction, IT/operations analysis, inventory control, MES/MRP, quality process analysis, work flow systems, and compliance monitoring by automation. Assume responsibility for account engagement and client improvement processes for all manufacturing (high tech, discrete) for a Tier 1/2 ERP vendor. Eliminate the waste of operations by revising MES/MRP system to lean methods.
• Develop current processes models, conduct assessments, document findings, identify gaps, analyze, measure maturity, and develop recommendations for implementation and improvement in business, operations, service, distribution, SCM, SDLC, CMMI, and production management processes based on best practices. Lead capacity planning analysis, process bottleneck, agile/lean initiatives and cost benefit analysis. ISO 9000/9001 preparation/audits and QMA planning. Also, develop, implement and direct the quality control and formal continuous improvement process. Lead auditor for ISO 9000:2001 quality audit...
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