JACOB VARGHESE
1611 W. Adamy Ct., Addison, IL 60101
708-369-8228 ~Cell; ; [Send email to request phone number] 67-0657 ~ Home
SENIOR EXECUTIVE
Operations & Quality Management ~ Project Management ~ Performance Improvement
Highly accomplished, adaptable management professional with 15+ years of
progressive success across stringently regulated industries (Automotive,
Injection Molding, Medical & Hydraulic/Fluid). Dedicated leader with broad range
of management and Six Sigma methodology skills that ensure rapid operational
adjustment to changing environments and requirements. Excellent analytical and
problem-solving abilities along with track record of achieving significant
quality and efficiency improvements. Demonstrated ability to forge and lead
high-performing teams as well as train and develop junior colleagues to achieve
proficiency and contribute to organization 's goals.
CORE COMPETENCIES
* Six Sigma Black Belt
* FMEA, PPAP. R&R, DOEs, APQP, Cntrl Pln
* Lean Tools (5S, Conduct Kaizen events)
* Vision & Leadership
* Statistical Process Control (SPC/Cpk )
* Quality Analyses & Initiatives
* Value Streaming Process
* Setting Operations goals
* Implementing Procedures & Standards
* KAN-BAN System (& Electronic Pull System) * Corrective Action (8D, 5Why,
5P,CAPA,4UP) & MRB
* Statistical Process Control
* Developing & Monitor Dept. Budget
* Root Cause Analysis
* Suppler Developments
* Supply Chain
* Improving Productivity
* Cost Saving
* Computer Literate * TQM & Kaizen Methods
* SQDC Monitoring
* Mentoring & Coaching
* Visual Factory mgmt.
* Managing Production
* ISO/QS/TS/QSR STDs.
* Eng./Mfg Drawings
* Safety Officer
* Plastic Injection Molding
* OSHA & Environmental Std.
EDUCATION & CREDENTIALS
MBA, Operations Management & International Business (2001) ~ Lake Forest
Graduate School of Management, Chicago, IL
BS, Industrial Engineering (1998), AS, Organizational Leadership & Supervision
(1997) ~ Purdue University, Hammond, IN
Trained Six Sigma Black Belt * University of Texas and Air Academy in Colorado
Spring
Certified QS9000, ISO/TS16949 Internal Auditor, ISO9001:2000/2008 & ISO 13485
(FDA)
Lean Tools (KAIZEN - Trained Instructor * 5S, VRK, Value Stream Mapping,
Standard Work, SMED, DMIAC, PDCA ...)
PROFESSIONAL EXPERIENCE
Anderson Fittings, Oak Forest, IL 2006 Sept -Current
Corporate, Director of QA & Operational Excellence, ISO & Continuous
Improvement/Safety
* Report to the President of the Company (Division of Marmon - Berkshire
Hathaway - Warren Buffet)
Direct all Quality and Operational Excellence functions across all facilities
focused on hydraulic brass & steel fittings manufacturing. . Partner with
President to set goals and budget for all divisions; assure compliance with all
internal/external guidelines and regulatory/safety requirements. Driving multiple
operations by leading a 6 methodology and Lean/continuous improvement
philosophy to reduce lead times, lower cost, and improve quality and safety.
Bench mark other industries for best practices. Run production responsibilities
as needed basis.
Lead all continuous improvement efforts; train, mentor and lead operational
excellence team to achieve greater goals. Resolve manufacturing and customer
quality issues; develop supplier quality / selection programs to minimize risks
and Vendor management.
Directly involved in Sales and Marketing functions.
Key Achievements:
˜ Achieved 50% reduction in defects (PPM) by using Lean and Six Sigma tools
($212,500 in scrap cost reduction)
˜ Increase the industry standard for PPM from 3.5 * 6 capability
˜ Implemented the 5S program ( including training and audit) & Standard work
Lean tools
˜ Conducted over fifteen 5S events - (Resulted in 30% more work space capacity
and improve mfg process flow and Efficiency)
˜ Conducted KAIZENs to improve Efficiency, Productivity, Delivery, and Cycle
time Reduction (combination of SMED, Std Work, 5S, Value Streaming,
Force-Ranking, VRK & Six Sigma Tools)
o 30% - 52% Reduction in set up time
˜ Implementation of Best-in-Class Manufacturing Practices,
Predictive/Preventive Maintenance and Preventive Action program (Improving
Productivity, efficiency, Safety, Quality, Team Moral...)
˜ Achieved Best Safety records ((Below BLS) through implementing best Safety
programs and/or practices (FMEA, PRA...)
˜ Standardize and stream line the ISO9001:2000 program in corporate level.
˜ Revised the SPC program and implemented training * Improved Ave Cpk from
1.1 to 2.6 and above
Gendex Imaging / KaVo Technologies / DEXIS, Des Plaines, IL 2004-2006
Corporate, Manager - QA, Safety & Continuous * 4 Divisions, North American
Operations * Division of Danaher Corporation (ISO/FDA Regulated) * Medical
Equipment Company (Mfg - X-Ray, Dental Surgical Instrument, and equipments)
Direct all Quality, Continuous improvements, and Safety functions and lead
members of the team across 4 different Operations/2 different facilities focused
on medical device manufacturing. Define and implement QA strategies and goals;
assure compliance with all internal/external guidelines and regulatory
requirements. Partner with President to set annual goals for all divisions;
create action plans. Lead continuous improvement efforts; train and mentor
cross-functional QA and operations personnel. Resolve manufacturing and customer
quality issues; develop supplier quality / selection programs to minimize
defects; develop and apply manufacturing validation procedures. Run production
responsibilities as needed basis
Key Achievements:
˜ Defined and implemented life test protocols to improve product reliability
during use.
˜ Achieved 50% reduction in defects and warranty costs by using Lean and Six
Sigma tools.
˜ Prepared for and led 4 divisions to pass stringent ISO 13485 audits (FDA).
˜ Attained 30% efficiency improvement with 50% workspace reduction by
implementing one-piece flow manufacturing process.
˜ Conducted variable reduction Kaizen project that reduced internal scrap by
60-70%.
˜ Implemented direct-to-stock program that achieved 60% receiving
inspections.
˜ Spearheaded introduction of Supplier Approval/Development process,
corrective action program, and SWAT team to provide rapid response to customers
' quality issues.
˜ Crafted key performance indicator matrix to manage daily operations.
Omron Automotive Electronics, Inc., St. Charles, IL 1998-2004
Manager, Supplier Quality Engineering & Incoming Inspection, 2002-2004
Supervisor, Quality Engineering / Assurance (ECU), 1998-2002
Promoted to manage dual role supervising 6-member team across 2 departments,
including supplier / production quality and incoming inspection. Prepared and
administered $500 -750K budget; developed quality procedures and
identified/implemented cost reductions. Evaluated and audited suppliers and
developed domestic/international supplier base. Developed supplier QA
initiatives, including ISO/TS16949 and QS 9000 compliance and related
activities.
Assembled and led Kaizen continuous improvement team to identify root causes and
implement corrective actions to contribute to zero-defect goals. Served as
primary liaison with key customers including Honda, Chrysler, Subaru-Isuzu, Ford,
General Motors, Mitsubishi, and others.
Key Achievements:
˜ Implemented Kaizen continuous improvement process, achieving dramatic
reduction from 17,000 to 900 PPM product defect levels for one product within 3
months.
˜ Developed and implemented visual factory management programs that
streamlined parts identification and reduced both time and scrap.
˜ Reduced handling defects and resultant product failures through use of
division-wide ESD training.
˜ Key negotiator in project that reduced claim costs by $825,000 during first
year.
˜ Pioneered on-site component localization teams to improve response to
customer needs, saving $575,000 annually, as well as initiatives resulting in
nearly $275,000 in additional annual savings.
˜ Reduced supplier notification time from 28 days to 2 hours and production
parts validation time from 42 to 3 days.
˜ Key member of cross-functional team driving APQP, new product launch, cost
reduction, and tool localization.
˜ Ensured ISO 9002/QS-9000/TS16949 compliance through use of internal
surveillance and supplier audits.
Automatic Spring Coiling, Chicago, IL 05/1997 * 12/1998
Senior Quality Engineer/Assistant Quality Assurance Manager * (Union Shop)
Directed daily operation of the QA department. Managed tool/gauge calibration
processes and database system. Supervised inspectors/technicians. Conducted
internal surveillance audits to maintain ISO 9002 and QS 9000 status. Performed
SPC process/machine capability audits (Datamyte) and trained QA staff/operators
in SPC.
Key Achievements: Played major role in implementing QS9000.
PCB Mfg., Electronic Support Systems, Chicago, IL 12/1995 * 03/1996
Quality Assurance Supervisor
Supervised quality assurance staff. Performed numerous statistical process
capability studies, and led first-article/in-process inspection processes.
Involved in preparation for ISO 9000 certification
D&B Auto Radios, Inc., Addison, IL 09/1991 * 11/1995
Re-manufacturer for Delco Electronics
Electronic Board Repair Specialist
PRIOR EXPERIENCE
Tietz & Baur, Inc., Chicago, IL 06/1989 * 09/1991
Injection Molding
Operator, Shift Supervisor
Julien Electricals, Inc., Chicago, IL 05/1988 * 05/1989
Injection Molding
Machine Operator/Die Set
ASQ Certifications:
QS-9000 ~ Six Sigma ~ ISO-9000 ~ Statistical Process Control (SPC) ~ GD&T ~
DOE-ANOVA
Chi-2-Test ~ F-Test ~ T-test ~ Taquchi Method ~ Hypothesis Test ~ Quality Cost ~
APQP
IPC Registered Instructor:
IPC-A-6 |
