Chief Operations Officer
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Results-driven and highly accomplished global manufacturing executive with over 20 years of multi-site manufacturing experience with start-up, change management, revitalization, cultural change, and turnaround operations, who has led the way for accelerated revenue gains of $2.6 billion by implementing cross-functional training and utilizing cutting-edge technologies for global organizations.
Certified Six Sigma Master Black Belt (MBB) and Lean Sensei that has operational quality excellence, boots-on-the-ground, sleeves-rolled-up, proactive leadership, with a hands-on mentoring approach, combined strategic sales, business, and astute financial skills; that has achieved a career-high of $550M in the reduction of scrap, customer defects, downtime, missed shipments, and turn-over rates (CoPQ) by implementing proven Best Practice manufacturing strategies, continuous improvement techniques, and Lean Six Sigma Innovations.
Decisive and innovative recipient of multiple sales, quality, and operational achievement awards; who is multi-lingual and highly valued for his expertise in the development of valuable relationships within American, European, Asian, and Latin American corporations for ensuring premium quality at the lowest possible cost while exceeding productivity, meeting on-time delivery, customer requirements, and surpassing the Board of Directors’ expectations.
Global Operations Leadership with Budgeting and Forecasting.
Quality Management with Global green-field startup experience.
Engineering Management with New product launches and positioning.
Operational Excellence (OpEx) with Lean Innovations.
Strategic Planning with Cross-functional Metric organizational development.
Profit & Loss (P&L) and Continuous Improvement projects with ROI.
Good manufacturing practices (GMP) with Performance evaluations.
Cross-cultural change, communications, and team development.
Executive account management with manufacturing distribution strategies.
Customer analytics with Voice of the Customer (VoC).
Global Supplier development with audits and Cost-down PPV projects.
Earnings Before Interest, Taxes, and Amortization (EBITDA).
Delivering value-added solutions to all levels of an organization.
Translating the Board of Directors’ vision & objectives into strategic actions.
Gap analysis with strategic cross-functional action plans.
Global business expansions with market analyses and assessments.
KPI development with PowerPoint presentations for all departments.
Process Improvements with Layered Process Audits (LPA).
Six Sigma Master Black Belt, Lean Six Sigma Sensei, Advanced CI Specialist, TPS (Toyota Production Systems), TQS (Total Quality Systems), TQM (Total Quality Management), TPM (Total Productive Maintenance), CQE (Certified Quality Engineer), CQA (Certified Quality Auditor), CQM (Certified Quality Manager), RCCA (Root Cause Corrective Action), Kaizen, Kanban-JIT (Just in Time), LPA (Layered Process Audits), EH&S (Environmental Health and Safety, HS&E (Health Safety and Environmental).
DMAIC principles, Lean tools, Continuous Improvement techniques, EBITDA, P&L, CapEx, OpEx, M&A, Kaizen, Kanban, CQE, CQA, CQM, IATF-16949, ISO/TS-16949, VDA, ISO-9000, ISO-9001, EN/AS-9100, ISO/IEC-17025, ISO-13053, ISO-13485, ISO-14001, OHSAS/ISO-18001, TPS, QS, QMS, TQS, TQM, OSHA, ESOS, EHS, HS&E, ERP, SAP, Oracle/NetSuite, CMMS, MRP, MES, SharePoint, Microsoft Suite, Microsoft 360, APQP, PPAP, MSA, PFMEA, SWP/SOP, Control Plans, SPC, MRB, PSL, 5S, 6S, VoC, CMM, ITAR, DoD, DAR, 8D, A3, PDCA, CAPA, LPA, and NDT.
01/02/2007 to Present
Advanced Operations and Quality Services – Global Operations
Chief Operations Officer for global Manufacturing
AO/QS LLC is a privately owned corporation that provides Quality, Operations, Continuous Improvement, Lean Innovations, Product Engineering, Production Engineering, Accounting, Training, and Sales consulting services within the Automotive, Commercial Vehicle, Aerospace, Military, Medical Device, Marine, Industrial, and Agricultural industries.
The following Corporate assignments and Executive titles during my tenure:
Vice President of Quality and Environmental Health & Safety – Las Vegas, Nevada – Two-year assignment
Directed the deployment of ERP, QMS, and EHS systems across three greenfield startups. Developed a comprehensive regulatory compliance strategy for all 50 states, achieving ISO 9001 certification in the first operational year with zero major findings.
Director of Global Operations, Quality, CI, Lean, and EH&S – 18 global facilities – CT, NC, MI, France, Germany, China – Three-year assignment
Engineered a global KPI platform and led seamless QMS transition from TS 16949 to IATF 16949, optimizing APQP processes and enhancing operational efficiency. Achieved an 8,000-point reduction in internal PPM, eliminated 80% of customer defects, reduced scrap by $18 million, resolved 95%+ of warranty returns, and established a dual-sourcing supplier evaluation system, increasing revenue by $68.9 million for a $1 billion global insulation leader.
Director of Global Operations, Quality, and EH&S – 26 global facilities – United Kingdom, France, Germany, Italy, MI, NC, GA – Two-year assignment
Established a unified KPI and quality system standardized to IATF-16949. Reengineered CAR/8D processes, delivering $4 million in savings, reducing internal CNQ from 6.7% to below 0.2%, cutting scrap by $6 million, and decreasing DMRs by 79% for a $7 billion Tier 1 manufacturer.
Director of Global Operations, Quality, CI, Lean, and EH&S – 14 global facilities – MI, KY, France, Germany, India, China – Three-year assignment
Implemented comprehensive turnaround strategies and rigorous performance evaluations, resulting in a 13,000-point reduction in internal PPM, $12 million in scrap and warranty return reductions, and $91.2 million in incremental revenue for a $1 billion Tier 1 electrical components supplier. These outcomes were pivotal in facilitating the company’s successful sale.
Executive Vice President of Global Quality – 17 global facilities – Shunde, China, Taishan City, China, KY, GA, TN – Three-year assignment
Directed the greenfield launch of an 11 million square foot advanced production facility, securing $2.62 billion in new contracts with major European and American clients for an $8 billion global enterprise.
Director of Global Operations, Quality and CI – 18 Global Facilities – Osaka, Japan, Canada, AL, IL – Two-year assignment
Orchestrate training on the Monozukuri system (TPS) for North American facilities, resulting in an average internal defects rate of $1.7 million. Reduce scrap and warranty returns by $4.9 million, and increase revenue by $21.2 million per facility for this Tier 1 global supplier.
Director of Operations, Quality, CI, and EH&S – 26 global facilities – UK, France, Germany, Italy, MI, SC, GA– Two-year assignment
Streamline operations by overseeing the startup of four gray and ductile iron foundries in South Carolina and Georgia, with these techniques and procedures rolled out to the other global facilities. Implement a robust TS16949 Quality System for a $14.9 billion global corporation.
Director of Corporate Quality, Operations, and Lean Expert – 12 global facilities – Ingwiller, France, Germany, China, NC – Two-year assignment
Consolidate three manufacturing facilities into a single advanced site in North Carolina, completing the transition three months ahead of schedule and saving $82 million. Transition the quality system from VDA to TS 16949 and develop a global KPI system, establishing a model now used for enterprise-wide integrations.
10/25/1999 to 12/31/2006
Blue Moon Architectural and Quality Services – Global Operations
BMAQS LLC is a privately owned corporation that provides executive management consulting services within manufacturing for the Automotive, Commercial Vehicle, Architectural, Marine, Aerospace, Military, Consumer Goods, Heavy Manufacturing, and Agricultural industries.
Director of Corporate Quality, Operations, and Lean Expert – 28 global facilities – Gerlingen, Germany, Italy, France, SC, MI, TN – Five-year assignment
Piloted a pivotal five-year assignment for a $13 billion Corporation and one of the largest Tier 1 suppliers to the automotive/commercial vehicle industry. Tackled a $200 million lawsuit by investigating and eliminating customer defects related to a thermal event, while steering the transition from ISO9001 to the new VDA German Quality standards and TS16949 for US Quality standards.
08/13/1990 to 10/25/1999
Oakwood Homes Corporation – North Carolina, Tennessee
Senior Architectural Manager of Engineering, Quality, and Continuous Improvement. Joined the world's largest modular home builder post-graduate as an Engineering Architectural Draftsman. Promoted three times within the first ten months, to Engineering, Quality, and Continuous Improvement Manager, overseeing four locations as I pursued a Master's degree in Engineering.
Executive MBA in Health, Safety, and Environmental (HS&E) / Advanced Quality Management Systems with ASQ Certifications
Medical University of South Carolina sponsored by Robert Bosch Corporation - Charleston, South Carolina GPA: 3.86
Masters of Science in Engineering / Quality Management Systems with ASQ Certifications
University of North Carolina sponsored by Oakwood Homes Corporation - Greensboro, North Carolina GPA: 3.82
Basic Officer Training (BOT) / Basic Law Enforcement Training (BLET)
North Carolina Justice Academy – Salemburg, North Carolina (Honors: Sharp Shooter and youngest inductee, PERT Team Member)
Bachelor of Science in Computer Science, Emphasis in Engineering and Quality Management Systems; Minor: International Finance
Pace University - White Plains, New York GPA: 3.68
